Pickleball paddles with stiffening features

Abstract

The invention described herein is a pickleball paddle having means to adjust the paddle bending stiffness as determined by bending displacement. The pickleball paddle comprises a head attached to a handle with a frame partially or completely surrounding the head. Externally or internally applied components may be added to the junction of the frame and handle to adjust the paddle bending displacement under load.

Description

Docket No. KMC-25-006-PCTPICKLEBALL PADDLES WITH STIFFENING FEATURESTECHNICAL FIELD

[0001] This disclosure relates generally to pickleball paddles and, more particularly, relates to features to control the stiffness of pickleball paddles.BACKGROUND

[0002] A pickleball paddle provides a head for striking a ball, and a handle attached to the head to allow users to manipulate the head to strike the ball.The head comprises a panel with a first and second striking face and a core fixed therebetween. The head further comprises a frame completely or partially surrounding the panel. The throat of the paddle is the junction between the handle and the frame and bears most of the stresses at impact.Users with different swing speeds and playing styles need different paddle bending stiffnesses. The junction between the frame and handle encompasses the paddle throat. Changing the mechanical properties of the frame and handle at the paddle throat will change the paddle bending stiffness. Therefore, pickleball paddles with stiffening adjustment mechanisms and features allow for the adjustment of throat mechanical properties to suit the needs of the user.BRIEF DESCRIPTION OF THE DRAWINGS

[0003] To facilitate further description of the embodiments, the following drawings are provided in which:

[0004] FIG. 1A illustrates a front view of a pickleball paddle with coordinate system.

[0005] FIG. IB illustrates a front view of the pickleball paddle of FIG. 1A.

[0006] FIG. 2 illustrates an exploded view of a pickleball paddle without thehandle.Docket No. KMC-25-006-PCT

[0007] FIG. 3 illustrates a front view of the head.

[0008] FIG. 4 illustrates a perspective view of the frame.

[0009] FIG. 5 illustrates a detailed view of the throat.

[0010] FIG. 6 illustrates a perspective view of the handle.

[0011] FIG. 7 illustrates an exploded view of the handle of FIG. 6.

[0012] FIG. 8 illustrates a front view of the grip.

[0013] FIG. 9 illustrates a detailed front view of the high stress area.

[0014] FIG. 10 illustrates a front, exploded view of a two-piece external stiffener.

[0015] FIG. 11 illustrates a perspective view of the two-piece external stiffener of FIG. 10.

[0016] FIG. 12 illustrates a front assembled view of the two-piece external stiffener of FIG. 10.

[0017] FIG. 13 illustrates a perspective view of an embodiment of an internal stiffener.

[0018] FIG. 14 illustrates a cut-away view of the internal stiffener of FIG. 13.

[0019] FIG. 15 illustrates a perspective view of an embodiment of an internal stiffener.

[0020] FIG. 16 illustrates a cut-away view of the internal stiffener of FIG. 15.

[0021] FIG. 17 illustrates a perspective view of an internal arm stiffener.

[0022] FIG. 18 illustrates a front cut-away view of the internal arm stiffener of FIG. 17.

[0023] FIG. 19 illustrates a front view of an external arm stiffener.

[0024] FIG. 20 illustrates a front perspective view of an applique stiffener.

[0025] FIG. 21 illustrates a side perspective view of the applique stiffener of FIG.Docket No. KMC-25-006-PCT

[0026] FIG. 22 illustrates a frame notch.

[0027] FIG. 23 illustrates an isometric view of a c-channel stiffener.

[0028] FIG. 24 illustrates a cross-section of the c-channel stiffener of FIG. 23.

[0029] FIG. 25 illustrates an isometric view of one half frame.

[0030] FIG. 26 illustrates two c-channel stiffeners in the one-half frame of FIG.25.

[0031] FIG. 27 illustrates two c-channel stiffeners assembled with a head.

[0032] FIG. 28 illustrates the assembly of FIG. 27 in one-half of a frame.

[0033] FIG. 29 illustrates a front view of an internal goblet throat stiffener.

[0034] FIG. 30 illustrates a top isometric view of the internal goblet throat stiffener of FIG. 29.

[0035] FIG. 31 illustrates an internal goblet throat stiffener assembled in one halfof a frame.

[0036] FIG. 32 illustrates an internal goblet throat stiffener.

[0037] FIG. 33 illustrates an exploded view of a paddle core and an internal goblet throat stiffener.

[0038] FIG. 34 illustrates a cross-sectional plan view of a paddle comprising an internal goblet throat stiffener.

[0039] FIG. 35 illustrates an enlarged perspective view of a paddle core with an internal goblet throat stiffener.

[0040] FIG. 36 illustrates an enlarged perspective view of a paddle core with an internal goblet throat stiffener and one frame component.

[0041] FIG. 37 illustrates a plan view of an internal stiffener comprising through apertures.

[0042] FIG. 38 illustrates a perspective view of the stiffener of FIG. 37.

[0043] FIG. 39 illustrates a side view of the stiffener of FIGS. 37 and 38.Docket No. KMC-25-006-PCT

[0044] FIG. 40 illustrates an exploded perspective view of a paddle comprisingthe internal stiffener of FIGS. 37-39.

[0045] FIG. 41 illustrates a cross-sectional plan view of the paddle of FIG. 40.

[0046] For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denote the same elements.DEFINITIONS

[0047] The terms “first,” “second,” “third,” “fourth,” and the like in the description and in the claims, if any, are used for distinguishing between similar elements and not necessarily for describing a particular sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances such that the embodiments described herein are, for example, capable of operation in sequences other than those illustrated or otherwise described herein.Furthermore, the terms “include,” and “have,” and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, device, or apparatus that comprises a list of elements is not necessarily limited to those elements but may include other elements not expressly listed or inherent to such process, method, system, article, device, or apparatus.

[0048] The terms “left,” “right,” “front,” “back,” “top,” “bottom,” “over,” “under,” and the like in the description and in the claims, if any, are used for descriptive purposes and not necessarily for describing permanent relative positions. It is to be understood that the terms so used areDocket No. KMC-25-006-PCTinterchangeable under appropriate circumstances such that the embodiments of the invention described herein are, for example, capable of operation in other orientations than those illustrated or otherwise described herein.

[0049] The term “centerward” as used herein, describes a direction toward the geometric center of the paddle.

[0050] The term “inward” as used herein describes a direction toward the coupling plane.

[0051] The terms “couple,” “coupled,” “couples,” “coupling,” and the like shouldbe broadly understood and refer to connecting two or more elements or signals, electrically, mechanically and / or otherwise.

[0052] The term “geometric centerpoint,” or “geometric center” of the face plate,as used herein, can refer to a geometric centerpoint of the face plate perimeter, and at a midpoint of the face height of the face plate.

[0053] The “length” of the pickleball paddle 100 head, as used herein, can be defined as a top-to-bottom dimension of the pickleball paddle. In many embodiments, the length of the paddle can be measured according to a pickleball governing body such as USA PICKLEBALL.

[0054] The term “face plate” of the pickleball paddle, as used herein, can refer toone or both of the face plates attached opposite one another with the core therebetween. The face plate is positioned external relative to the core and may be externally exposed to form the striking surface or hitting surface, or may be covered by an added hitting surface.

[0055] The term “frame internal cavity” as used herein, refers to the void definedby the interior surfaces of the first and second frame members.

[0056] The term “paddle deflection stiffness” as used herein, refers to the resistance of a paddle secured at the handle to a 7 pound cantilever force pressing against the paddle surface perpendicular to a face plate at a centerDocket No. KMC-25-006-PCTpoint of the paddle top edge. The paddle deflection stiffness is measured as a paddle top edge center deflection distance from a starting plane parallel to a ground plane.

[0057] The term “paddle throat” or “throat” as used herein, refers to the juncture between the paddle frame and the handle. The throat arms (alternatively called arms) attach to the frame lateral sides and join together adjacent to the paddle handle upper portion.

[0058] The term “high stress area” as used herein, refers to an area between and including the throat arms within a paddle head lower portion.

[0059] An “XYZ” coordinate system of a pickleball paddle, as used herein, is based upon the geometric center of the exposed face plate. The pickleball paddle 100 face dimensions as described herein can be measured based on a coordinate system as defined below. The geometric center of the exposed face plate defines a coordinate system having an origin located at the geometric center of the exposed face plate. The coordinate system defines an X axis 20, a Y axis 30, and a Z axis. The X axis 20 extends through the geometric center of the exposed face plate, and through the lateral edges108 of the paddle face. The Y axis 30 extends through the geometric center of the exposed face plate in a direction from the butt end to upper rim of the pickleball paddle 100 head. The Y axis 30 is perpendicular to the X axis 20. The Z axis (not shown) extends through the geometric center of the exposed face plate in a direction from one face plate to the other on the pickleball paddle 100 head. The Z axis is perpendicular to both the X axis20 and the Y axis 30, extending in a front to back direction.

[0060] The XYZ coordinate system of the pickleball paddle 100 head, as used herein defines an XY plane extending through the X axis 20 and the Y axis30. The coordinate system defines XZ plane extending through the X axis20 and the Z axis. The coordinate system further defines a YZ plane extending through the Y axis 30 and the Z axis. The XY plane, the XZDocket No. KMC-25-006-PCTplane and the YZ plane are all perpendicular to one another and intersect at the coordinate system origin located at the geometric center of the head105. In these or other embodiments, the pickleball paddle 100 can be viewed from a front view when the face plate is viewed from a direction perpendicular to the XY plane. Further, in these or other embodiments, the pickleball paddle 100 head can be viewed from a side view or side cross- sectional view when the lateral edge 108 is viewed from a direction perpendicular to the YZ plane.DESCRIPTION

[0061] Discussed herein are pickleball paddles with stiffening adjustment structures positioned adjacent the paddle throat. A head lower portion encompassed by handle arms transitioning to the paddle frame bears the majority of the stresses between the handle and the head. The stiffening adjustment mechanisms of the present invention provide adjustability in stiffness within that high stress area, while being light weight to prevent excessive loss of discretionary mass and to limit change of the location of the center of gravity (CG) location. Further, the positioning, placement, and attachment means of the stiffening adjustment mechanisms ensure the pickleball paddle remains aesthetically pleasing to the user.

[0062] Pickleball paddle users vary in their strength, swing speed, and how much tactile feedback they deem desirable when striking a pickleball. Deflection stiffness (hereafter referred to as “stiffness”) is at least one measure of the mechanical properties of the pickleball paddle 100 that can be modified by changing the stiffness of the pickleball paddle 100 within the high stress area 170. Deflection stiffness is characterized by an object’s ability to resist deflection when a load is applied. One or more stiffness modifying structures can be added within throat arms (127, 129) and throat 125 to alter the deflection stiffness of the pickleball paddle. In some embodiments, this allows a portion of pickleball paddle 100 having aDocket No. KMC-25-006-PCTstandard stiffness to be modified to a paddle having a larger stiffness. The standard stiffness of the adjustable stiffness paddle 100 would be the lowest stiffness, rising with the addition of one or more stiffness modifying structures. Users with different swing speeds and playing styles need different stiffness and rigidity in the high stress area to fit their needs. The pickleball paddle 100 described herein provides adjustability in resistance to bending (i.e. bending stiffness) within that high stress area 170, tailoring it to the individual needs of each user with respect to properties including: power, forgiveness, and trajectory manipulation.

[0063] As best shown in FIGS. 1-9, the pickleball paddle 100 comprises a head105, a frame 115 including a throat 125 coupled to the head 105, a handle coupled to or integral with the frame 115, and a grip 160 covering the handle 150 to provide a gripping surface for the user’s hand or hands, which is also shown in FIG. 8. The paddle comprises a maximum paddle width 141 and a maximum paddle height 140. The head 105 comprises a front face plate 109, a rear face plate 110 opposite the front face plate 109, and a core 112 between the front face plate 109 and the rear face plate 110.A perimeter of the core 112 is housed within a cavity defined, at least in part, by the frame 115, the front face plate 109, and the rear face plate 110, as best shown in FIGS. 2 and 3.

[0064] The frame 115 comprises a frame outer perimeter 116 and a frame inner perimeter 117. The frame 115 further comprises at least one of a frame top edge 121, a first frame lateral edge 122, a second frame lateral edge opposite the first frame lateral edge 122, and a frame bottom 124. A frame width 118 is measured as a shortest distance through the frame, from a first exterior point on the frame outer perimeter 116 to a second exterior point on the frame inner perimeter 117. The frame 115 further comprises a frame front surface 119 positioned, in part, on the front face plate, and a frame rear surface 113 opposite the frame front surface 119 positioned, in part,Docket No. KMC-25-006-PCTon the rear face plate 110. A frame thickness 120 is a maximum distance measured in a direction parallel to the YZ plane between an outermost point on the frame front surface 119 and an outermost point on the frame rear surface.

[0065] The frame further comprises a throat, which defines the transition betweenthe handle and the head, where most of the stress accumulates from impact.The throat 125 may be adjacent to a portion of the frame that is y-shaped, u-shaped, bowl-shaped, semi-circularly shaped, parabolically shaped, or elliptically shaped. As best shown in FIG. 5, the throat 125 of the frame115 comprises a throat upper edge 126, a first throat arm 127 having a first throat arm upper edge 128, and a second throat arm 129 extending opposite the first throat arm 127 having a second throat arm upper edge 130. The frame 115 comprises a throat stem 131 and a throat junction 132. The throat junction 132 adjoins the first throat arm 127, second throat arm 129, and throat stem 131. The first throat arm upper edge 128 is adj acent to the first frame lateral edge 122, and the second throat arm upper edge 130 is adjacent to the second frame lateral edge 123. A handle upper end 151 is adjacent to and connected with the throat stem 131. A handle lower end152 further comprises the handle 150 or paddle butt end 101. A handle body 153, configured to be gripped by the user, extends between the handle upper end 151 and the handle lower end 152.

[0066] The throat upper edge 126 may be located at the frame bottom 124. The throat 125 comprises a throat exterior surface and a throat interior surface.The throat junction interior surface may surround a hollow interior. In some embodiments, the core comprises a core extension 111 that extends into at least the throat junction 132 and may extend into the handle 150. As best shown in FIG. 9, the high stress area 170 is defined as the area between- and sometimes encompassing - the first throat arm upper edge 128 and the second throat arm upper edge 130. In use, the largest amount of stressDocket No. KMC-25-006-PCTa paddle endures occurs within this high stress area 170. Segments of both the frame 115 and the head 105 bear the stress load in the high stress area170. The paddle deflection stiffness is largely determined by the properties of the high stress area 170.

[0067] A stiffness modifier (hereafter “stiffener”) can be within or attached to a surface of the throat arms and throat junction. The stiffener addresses the high stress area 170 of the throat 125. In some embodiments described below, the structural support of the stiffener reinforces the first throat arm127 and the second throat arm 129. Depending upon the design as discussed below, the stiffener can be tailored to achieve a particular deflection stiffness of the throat / lower hitting surface of the paddle depending upon whether the user wants power, forgiveness, or shaping of shots.STIFFNESS MODIFYING STRUCTURES

[0068] The stiffener can be associated with the paddle externally, internally or a combination thereof. The stiffener can be a one-piece or two piece structure that either is interconnected on the butt end of the handle or over the paddle throat region. The external stiffener can be in a two piece construction along each arm of the throat. The external stiffener may be inserted into external arm apertures formed within each of the first and second throat arms. The stiffener can be an integrated piece that is inserted within the throat of the paddle and harbored within the first and second throat arm and throat stem. The stiffener can comprise ribs, bosses, slots or other deflection maneuvering structures that alter the paddle deflection stiffness. The stiffener can be adhesively joined or mechanically joined with snap-fit or mechanical fasteners.

[0069] The stiffener can be placed in the high stress area 170 and the design of the stiffener can be used to selectively tailor the stiffness of the throat, changing the paddle deflection stiffness. Each of the stiffness modifyingDocket No. KMC-25-006-PCTstructures also comprises a stiffener mass that can affect the overall paddle mass and the location of the CG. Because the stiffener is positioned below the paddle center of gravity, it will shift the CG down lower on the paddle.A CG located lower can increase control for users who prioritize control over power. A lightweight stiffener can minimize downward shifting of the CG. Furthermore, weight can be positioned near the top of the paddle using other means, to balance the counteract the stiffener’s impact on CG position. Positioning the CG above the geometric center of the paddle can increase power.

[0070] Pickleball paddles having no stiffener may a have a paddle deflection stiffness between 0.2 inch and 1.0 inch. Paddles lacking a stiffener may have a paddle deflection stiffness of 0.2 inch, 0.3 inch, 0.4 inch, 0.5 inch,0.6 inch, 0.7 inch, 0.8 inch, 0.9 inch, or 1.0 inch. A stiffener, as further described below, may change the paddle deflection stiffness in a range inclusively between 0.05 inch and 0.60 inch. The stiffener can change the paddle deflection stiffness over a paddle lacking a stiffener by 0.05 inch, 0.10 inch, 0.15 inch, 0.20 inch, 0.25 inch, 0.30 inch, 0.35 inch, 0.40 inch, 0.45 inch, 0.50 inch, 0.55 inch, or 0.60 inch (i.e. less deflection). The stiffener can add 10%, 15%, 20%, 25%, 30%, or 35% greater stiffness to the paddle. The stiffener can reduce standard test deflection vs. the test deflection of a paddle without a stiffener by 10%, 15%, 20%, 25%, 30%, or 35%.Two-Piece External Stiffness Modifying Structure

[0071] In one embodiment, an external stiffening structure may be fit over all orpart of the high-stress area. As best shown in FIGs. 10-12, a stiffener 200 comprises two pieces that assembly to each other and over the exterior of the throat 125 increases the paddle deflection stiffness. The paddle throat outer surface 133 receives the interior surface 204 of the external stiffener 200. The stiffener 200 comprises a stiffener 200 outer surface 202 and aDocket No. KMC-25-006-PCTstiffener interior surface 204. Each piece of the two-piece external stiffener200 comprises a first external stiffener arm 208 and a second external stiffener arm 210 that cooperate to wholly or partially cover the first throat arm 127 and second throat arm 129, respectively. Each piece of the two- piece external stiffener further comprises an external stiffener stem that wholly or partially covers the throat stem. The stiffener 200 comprises a stiffener thickness 206 measured perpendicularly between any point on the outer surface 202 and corresponding point on the stiffener interior surface 204. The stiffener thickness may be in a range inclusively between 0.05 inch and 0.25 inch.

[0072] The stiffener 200 comprises a stiffener 200 material. The two piece external stiffener comprise an arm stiffener material that can be chosen from a polymeric material, a carbon fiber composite material, or a metallic material. In many embodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer or metallic material. The stiffener 200 material may vary to increase or decrease the stiffener 200 material mechanical properties. The stiffener interior surface 204 may comprise ribs, bosses, slots, or other features to further alter the paddle deflection stiffness by adding more structural support. The two pieces of the external stiffening structure 200 may be adhesively joined, mechanically joined with snap-fit features or mechanical fasteners, or by both methods around the paddle throat 125. In some embodiments, the two pieces can be adhesively joined together, but not adhered to the other paddle components. In other embodiments, the two pieces can be adhered to one another and also to the head.Docket No. KMC-25-006-PCT

[0073] The degree to which the stiffener 200 increases the total paddle deflection stiffness may vary, depending on the stiffener thickness 206, stiffener internal surface features, or stiffener material properties. In this way, the stiffener 200 may change the paddle deflection stiffness by 10% or more.Internal Throat Stiffener

[0074] The pickleball paddle frame 115, throat 125, and handle 150 may be assembled from multiple, mating components, as best shown in FIGS. 6 and 7, the defines a frame internal cavity, freeing up discretionary mass for distribution elsewhere on the paddle 100. For such a frame, a throat stiffener 300 may be inserted in the internal cavity of throat 125 and / or the handle 115 of the paddle prior to assembling the frame components.Referring to FIGs. 13-16, a throat stiffener 300 comprises a first throat stiffener arm 302 and a second throat stiffener arm 304. The throat stiffener arms 302, 304 extend upward and outward at opposite angles from a throat stiffener stem 306 at throat stiffener junction 308, forming a ‘Y’ shape.The first throat stiffener arm 302, second throat stiffener arm 304, and throat stiffener stem 306 are integrally formed, creating a single, monolithic part. The throat stiffener stem 306 can extend into the throat stem 131 and sometimes into the handle 115. Each side of the multicomponent frame 115 is configured to receive the mechanically and / or adhesively affixed throat stiffener 300, such that the throat stiffener 300 is in contact with interior surfaces of all portions of the multi-component frame throat 125. The first throat stiffener arm 302 and second throat stiffener arm 304 extend within the first throat arm 127 and second throat arm 129, respectively.

[0075] In many embodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, a vitrimeric material, or a metallic material. In someDocket No. KMC-25-006-PCTembodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer or metallic material.Insertable Internal Throat Arm Stiffeners

[0076] As noted above, the high stress area 170 encompasses the throat 125.Adding structural support to the first throat arm 127 and the second throat arm 129 increases the stiffness of the throat 125 and the overall deflection stiffness of the paddle 100. Referring to FIGs. 17 and 18, internal throat arm stiffeners 400 may be inserted into each of the first and second throat arms (127, 129) through external arm apertures 402 connected to internal arm cavities 404. The internal arm cavities 404 may be blind holes. The internal arm stiffeners may snap-fit within the internal arm cavities 404.The internal arm stiffeners 400 may be retained within the internal arm cavities 404 by an arm aperture cap (not shown) sealing the external arm apertures 402. The internal throat stiffeners 400 may be rods having a circular, elliptical, or polygonal cross section. The internal throat stiffeners400 may be relatively flat, having a popsicle-stick shape. The internal arm stiffeners 400 may be adhesively or mechanically retained within the internal arm cavities 404. The internal arm stiffeners 400 may be permanently affixed or may be removable. The internal arm stiffeners 400 comprise an arm stiffener material that can be chosen from a polymeric material, a carbon fiber composite material, or a metallic material. A variety of arm stiffeners 400 may be available for insertion into the throat arms (127, 130) and chosen based on the target deflection stiffness of the pickleball paddle 100. The internal arm stiffeners 400 support the first and second throat arms (127, 129) to increase the stiffness of the throat 125 and provide an overall increase in stiffness of the paddle 100.Docket No. KMC-25-006-PCT

[0077] In many embodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer, vitrimeric, or metallic material.External Throat Arm Stiffeners

[0078] The paddle throat 125 may comprise external slots or channels 502 extending into each throat arm from the throat outer surface 133. The slots or channels 502 are recessed from the throat outer surface 133, and extend at least partly through the frame wall thickness 120 between the paddle interior surface 104 and paddle exterior surface 102. In some embodiments, the slots or channels 502 may be through slots, communicating with a paddle frame internal cavity 114. The slots 502 may be only on the front throat surface 135 or on both the front and rear external throat surfaces (135, 136).

[0079] As best shown in FIG. 19, an external arm stiffener 500 may be insertedinto an external slot 502, adding the mechanical properties of the external arm stiffener 500 to the existing mechanical properties of the pickleball paddle throat 125. The external arm stiffener 500 may extend between the first and second throat arm upper edges (128, 130) and into the paddle handle 150 or extend to a lesser extent within those boundaries, as shown in the embodiment of FIG. 19. Like the internal arm stiffeners 400, the external arm stiffeners 500 may snap-fit within the external slots 502. The external arm stiffeners 500 may be adhesively or mechanically retained within the external slots 502. The external arm stiffeners 500 may be permanently affixed or may be removable. The external arm stiffeners 500 comprise an arm stiffener material that can be chosen from a polymeric material, a carbon fiber composite material, or a metallic material. In manyDocket No. KMC-25-006-PCTembodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer, vitrimer, or metallic material.

[0080] A variety of external arm stiffeners 500 may be available for insertion intothe external slots 502 and chosen based on the target deflection stiffness of the pickleball paddle 100. The external throat stiffeners 500 support the first and second throat arms (127, 129) to increase the stiffness of the throat125 and provide an overall increased stiffness of the paddle. An advantage of the external stiffeners 500 is that it can provide a customizable stiffness based upon the user or manufacturer inserting external arm stiffeners 500 that comprise the desired degree of stiffness, which can be selectively modified by material and / or structure.Bonded Applique

[0081] External appliques 600 can be used also to customize the rigidity of the throat and overall paddle stiffness. Rather than a slot or channel that is recessed from the paddle exterior surface 102, a bonded applique (also referred to as an “external applique”) 600 may be applied to the paddle exterior surface 102, protruding from the exterior surface. Referring to FIGs. 20 and 21, a bonded applique 600 may be applied to the paddle throat junction 132, to each of the throat arms (127, 129), or across both arms and the throat junction 132. Bonded appliques 600 can also be designed to reinforce the throat arms and have an array of various stiffnesses based upon variable materials, such as polymers or elastomers, that can be tailored as discussed above and below. The bonded applique 600 may be adhesively attached to the paddle exterior surface 102 after the frame 115 is molded, or co-molded along with the paddle frame 115. The bondedDocket No. KMC-25-006-PCTapplique 600 comprises an applique material, an applique thickness 610, and an applique surface area.

[0082] The applique material may be a polymeric material, a carbon-fiber composite, or a metallic material. In many embodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer, vitrimer, or metallic material. Each material will have its own material properties and therefore each material will vary the throat stiffness differently. A material having higher bending stiffness will increase the deflection stiffness of the paddle 100 more than a material having a lower bending stiffness. The applique thickness 610 will affect the degree to which the applique will change paddle deflection stiffness.A thicker applique will increase the deflection stiffness of the paddle more than a thinner applique of the same design and material. The bonded applique 600 may have a uniform thickness. The bonded applique 600 may have a thickness that varies in different portion of the applique. In some embodiments, the bonded applique 600 may have a variable thickness that is greatest at the throat junction 132. Similarly, with material and thickness held constant, an applique having a larger surface area will increase the deflection stiffness of the paddle 100 more than an applique with a smaller surface area of the same thickness and material.

[0083] In some embodiments, the bonded applique 600 can have a maximum thickness of 0.05 inch to 0.25 inch. In some embodiments, the bonded applique 600 maximum thickness can be 0.05 inch to 0.1 inch, 0.1 inch to0.15 inch, 0.15 inch to 0.2 inch, or 0.2 inch to 0.25 inch. In some embodiments, the bonded applique 600 thickness can be less than 0.05Docket No. KMC-25-006-PCTinch, less than 0.10 inch, less than 0.15 inch, less than 0.20 inch, or less than 0.25 inch.Frame Notches

[0084] The throat arm wall thickness and surface area of the throat can be variableso as to guide the location and extent of deflection. As each throat arm(127, 129) extends upward toward the paddle frame top edge, the arm comprises a thickness 120 measured perpendicularly between the throat front and rear external surfaces (135, 136). Further, as best shown in FIG.4, each throat arm (127, 129) comprises a throat arm width 118 measured perpendicularly between the outer perimeter 116 and the inner perimeter117. Referring to FIG. 22, reducing either the arm thickness 120 in one location with a notch 700, in comparison to the surrounding arm thickness120, or alternatively, reducing a portion of the arm width 118 in one location with a notch 700, in comparison to the surrounding arm width 118, will reduce the relative stiffness of the throat arm in that location. Thus, the deflection stiffness of the paddle may be reduced from a standard stiffness to a lesser stiffness by forming notches 700 in the paddle throat arms (127, 129). More than one notch 700 may be formed. Notches 700 that are symmetrically placed relative to the Y axis 30, produce a balanced change of the paddle deflection stiffness.C-Channel Internal Stiffener

[0085] Another embodiment of a stiffener internal to a hollow frame comprises a cross-sectional shape particularly suited to increasing paddle deflection stiffness. An internal stiffener comprising a c-channel cross-sectional shape increases stiffness and provides a large surface for adhesive bonding while minimizing stiffener mass. Referring to FIGs. 23-28, a pair of c- channel stiffeners 800 comprises a first c-channel stiffener 820 and a second c-channel stiffener 822. The first and second c-channel stiffeners are mirror images of one another. Each c-channel stiffener 800 comprisesDocket No. KMC-25-006-PCTa c-channel vertical wall 802 connecting a pair of c-channel horizontal walls 804. The c-channel vertical wall 802 comprises a c-channel vertical wall height 810 parallel to the Z axis. Each c-channel horizontal wall 804 comprises a c-channel horizontal wall width 812 extending parallel to each other and parallel to the XY plane toward the paddle Y axis 30. The channel 824 is defined by the two horizontal walls 804 and the vertical wall 802. The channel 824 opens inward, towards the paddle frame interior cavity 114 and forms the channel inner surface 826. The channel outer surface 828 is opposite the channel inner surface 826. The channel thickness 808 is measured perpendicularly between the channel inner surface 826 and the channel outer surface 828.

[0086] The c-channel stiffener 800 comprises a c-channel upper arm 814 extending essentially parallel to the Y axis 30, a c-channel lower arm 818 extending essentially parallel to the Y axis 30, and a c-channel curved portion 816 between and connecting the c-channel upper arm 814 to the c- channel lower arm 818. The c-channel 800 conforms to the shape of the frame outer perimeter 116 where it is within the frame 115. The c-channel stiffener 800 comprises a c-channel arc-length 806 measured along the c- channel vertical wall 802, which follows the contour of the paddle head.The c-channel arc-length 806 is in a range between 3.0 inches and 8.0 inches. The c-channel arc-length may be 3.0 inches, 3.5 inches, 4.0 inches,4.5 inches, 5.0 inches, 5.5 inches, 6.0 inches, 6.5 inches, 7.0 inches, 7.5 inches, or 8.0 inches.

[0087] The channel 824 is configured to enfold the core outer perimeter, bondingto both the core 112 and frame 115. The channel horizontal walls 802 may be exposed on the paddle exterior. The channel horizontal walls 802 may be covered by the paddle front and rear face plates (109, 110).

[0088] In many embodiments, the c channel can be formed from one or more ofthe following materials: a polymeric material, a fiber-reinforced compositeDocket No. KMC-25-006-PCTmaterial, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer, vitrimer, or metallic material. In some embodiments, the c channel 824 can be fdled with another material. In some embodiments, the fdl material can comprise an expandable foam, a pre-cut foam, a polymeric injectable or pre-formed material, or a lightweight rigid material, such as wood, plastic, or metal.Goblet Internal Stiffener

[0089] The frame 115 may be injection molded with a single material. As discussed above, it may be desirable to add stiffening structures to the throat 125 to adjust the impact response within high stress area 170. A stiffener that partially or fully internally supports the throat 125 may provide the desired mechanical strength adjustment. Referring to FIGs 29- 36, an internal goblet throat stiffener 900 internally supports the entire throat 125. The internal goblet throat stiffener 900 comprises a goblet throat stiffener external surface 902 and a goblet throat stiffener internal surface 904. The goblet throat stiffener 900 further comprises a first goblet throat stiffener arm 906 and a second goblet throat stiffener arm 908 extending upward from the goblet throat stiffener junction 910. The goblet throat stiffener 900 further comprises a goblet throat stiffener lower extension 912 extending downward from the goblet throat stiffener junction 910. The goblet throat stiffener junction 910 and goblet throat stiffener lower extension 912 define a blind hole goblet throat stiffener cavity 914 having an upper opening and a closed bottom. The goblet throat stiffener cavity 914 is configured to receive the head extension 111.

[0090] The goblet throat stiffener 900 is configured to fit within the throat 125.Referring to FIG. 31, the first and second goblet throat stiffener arms (906, 908) fit within and surrounded by the first and second throat arms (127, 129). The goblet throat stiffener junction 910 and goblet throat stiffenerDocket No. KMC-25-006-PCTlower extension 912 are within and surrounded by throat junction 132 and throat stem 131. The throat interior surface 134 surrounds and is in contact with the goblet throat stiffener external surface 902. The goblet throat stiffener 900 may be mechanically press-fit into the throat 125. The goblet throat stiffener 900 may be adhesively secured with the throat 125.

[0091] The goblet throat stiffener arms (906, 908) comprise a c-channel cross section. The c-channel cross section provides a cupping support of the contacted head perimeter, allowing stresses placed on the head to be transferred to the goblet throat stiffener 900. The c-channel cross section comprises two goblet throat stiffener arm horizonal walls 916 parallel to the goblet throat stiffener external surface 902 and a goblet throat stiffener arm vertical wall 918 perpendicular to the horizontal walls 916 and parallel to the frame outer perimeter 116. The goblet throat stiffener arm vertical wall 918 connects the two goblet throat stiffener arm horizonal walls 916.The horizontal walls 916 and vertical wall 918 define a channel oriented inwards towards and overlapping the head 105.

[0092] The goblet throat stiffener 900 may comprise a carbon fiber composite, a metallic alloy, or a fiber-filled thermoplastic. In the case of the carbon fiber composite, fiber strength, fiber orientation, and number of layers may be altered to provide more or less stiffness. In some embodiments, the goblet throat stiffener 900 can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, a vitrimer, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer or metallic material.Internal Stiffeners Having Through Apertures

[0093] Another embodiment of a stiffener internal to a hollow frame comprises apair of stiffeners 1000 having through apertures 1020. The apertures in theDocket No. KMC-25-006-PCTstiffeners reduce the total mass of the stiffeners, provide a means of tuning the stiffness by removing material from the stiffeners, and serve to support and center a core extension 111 within the paddle throat 125 and handle150. As shown in FIG. 41, the pair of stiffeners 1000 are placed within the paddle frame 115 opposite from one another, adjacent the throat 125 and bracket the core extension 111. The pair of stiffeners 1000 are not exposed to the exterior. The through apertures 1020 extend entirely through the stiffeners in a front to back direction. The stiffeners 1000 comprise a stiffener outer side 1008 adjacent the paddle exterior and a stiffener inner side 1006 adjacent the paddle core.

[0094] The stiffeners 1000 comprises a stiffener top end 1004 distal the paddlebutt end 101 and a stiffener bottom end 1002 opposite the stiffener top end 1004. The stiffeners 1000 comprise a stiffener width 1014 measured perpendicularly from the stiffener outer side 1008 towards the stiffener inner side 1006. The stiffener width 1014 varies between the stiffener top end 1004 and the stiffener bottom end 1002. The stiffener width ranges between 0.10 inch and 0.75 inch. The stiffeners 1000 comprise a stiffener thickness measured perpendicularly from a frontward stiffener outer surface to a rearward stiffener outer surface. The stiffener thickness varies in a range between 0.10 inch to 0.75 inch. In some embodiments, as shown in the embodiment illustrated in FIGS. 37 and 38, the thickest portion of the stiffener 1000 can be positioned at the curve. This can strengthen the bend to reduce likelihood of failure and increase overall stiffness.

[0095] The apertures 1020 have a generally circular aperture cross section. The apertures 1020 have an aperture diameter measured perpendicularly from any point on an aperture inner surface to a point opposite on the aperture inner surface. The aperture diameter 1022 may be constant through any given aperture 1020. The aperture diameter 1022 may vary through any given aperture 1020. The aperture diameter 1022 may vary between anyDocket No. KMC-25-006-PCTtwo different apertures 1020. The apertures 1020 may comprise 2-25 apertures between the stiffener top end 1004 and the stiffener bottom end 1002.

[0096] The apertures 1020 can further increase security of the stiffener 1000 by providing additional fastening means. In some embodiments, an adhesive- sometimes in the form of an expandable foam or an epoxy - can fill the apertures 1020, locking the stiffeners into place.

[0097] The stiffener mass of any stiffener embodiment is in a range between 0.5 grams and 25.0 grams. The stiffener mass may be 0.5 gram, 1.0 gram, 1.5grams, 2.0grams, 2.5grams, 3.0grams, 3.5grams, 4.0grams, 4.5grams, 5.0grams, 5.5grams, 6.0grams, 6.5grams, 7.0grams, 7.5grams, 8.0grams,8.5 grams, 9.0grams, 9.5 grams, lO.Ograms, 10.5grams, ll.Ograms11.5grams, 12.0grams, 12.5grams, 13.0grams, 13.5grams, 14.0grams 14.5grams, 15.0grams, 15.5grams, 16.0grams, 16.5grams, 17.0grams 17.5grams, 18.0grams, 18.5grams, 19.0grams, 19.5grams, 20.0grams 20.5grams, 21.0grams, 21.5grams, 22.0grams, 22.5grams, 23.0grams 23.5grams, 24.0grams, 25.5grams, or 25.0 grams. In many embodiments, the stiffener can be formed from one or more of the following materials: a polymeric material, a fiber-reinforced composite material, a vitrimeric, or a metallic material. In some embodiments, the stiffener can be made from any one or combination of the following materials: PLE, ABS, PVC, aluminum, titanium, steel, or another suitable polymer, vitrimer, or metallic material.Examples

[0098] A pickleball paddle having no added stiffeners had a paddle deflection stiffness of 0.90 inch. The same pickleball paddle had an external stiffener applied similar to the stiffener 500 as described above. The original paddle deflection stiffness of 0.90 inch was reduced to 0.60 inch for a paddle deflection stiffness change of 30%. In addition, players noted a perceptionDocket No. KMC-25-006-PCTof greater power and control in the paddle having the stiffener vs. the paddle without the stiffener.

[0099] Replacement of one or more claimed elements constitutes reconstructionand not repair. Additionally, benefits, other advantages, and solutions to problems have been described with regard to specific embodiments. The benefits, advantages, solutions to problems, and any element or elements that may cause any benefit, advantage, or solution to ocm3ur or become more pronounced, however, are not to be construed as critical, required, or essential features or elements of any or all of the claims, unless such benefits, advantages, solutions, or elements are stated in such claim.

[0100] Moreover, embodiments and limitations disclosed herein are not dedicatedto the public under the doctrine of dedication if the embodiments and / or limitations: (1) are not expressly claimed in the claims; and (2) are or are potentially equivalents of express elements and / or limitations in the claims under the doctrine of equivalents.

Claims

Docket No. KMC-25-006-PCTCLAIMS1. A pickleball paddle, comprising:a head comprising:a front striking surface;a rear striking surface opposite the front striking surface; anda core between the front striking surface and the rear striking surface;a frame coupled to the head, comprising:a frame top edge;a first frame lateral edge;a second frame lateral edge;a handle having a handle upper end, a handle butt end opposite the handle upper end, and a handle body extending between the handle upper end and the handle butt end; anda throat defining a transition between the first and second frame lateral edges and the handle, the throat comprising:a first throat arm adjacent the first frame lateral edge;a second throat arm adjacent the second frame lateral edge; anda throat stem adjacent the handle upper end; wherein the first throat arm, the second throat arm, and the throat stem are coupled together at a throat junction and oriented in a substantially Y-shape; anda stiffness modifying structure associated with the throat and following a general contour of the throat.

2. The pickleball paddle of claim 1, wherein:the throat comprises a throat outer surface; andDocket No. KMC-25-006-PCTthe stiffness modifying structure is coupled to the throat outer surface to provide an external stiffness modifying structure.

3. The pickleball paddle of claim 2, wherein the external stiffness modifying structure comprises a two-piece external stiffener wherein each piece of the two-piece external stiffener comprises an interior configured to receive one half of the throat; andwherein the two-piece external stiffener is configured to snap fit over the throat.

4. The pickleball paddle of claim 2, further comprising a first external slot extending from the throat outer surface into the first throat arm, and a second external slot extending from the throat outer surface into the second throat arm, wherein the stiffness modifying structure comprises a first external arm stiffener disposed in the first external slot and a second external arm stiffener disposed in the second external slot.

5. The pickleball paddle of claim 4, wherein the first and second external arm stiffeners are respectively coupled to the first and second external slots by a snap-fit connection, an adhesive, or a mechanical retainer.

6. The pickleball paddle of claim 4, wherein each of the first and second external arm stiffeners comprises an arm stiffener material chosen from a polymeric material, a carbon fiber composite material, or a metallic material.

7. The pickleball paddle of claim 2, wherein the external stiffness modifying structure comprises an external applique bonded to the throat outer surface.

8. The pickleball paddle of claim 7, wherein:the external applique extends across the first throat arm, the second throat arm, and the throat stem; andthe external applique comprises a variable thickness that is greatest at the throat junction.Docket No. KMC-25-006-PCT9. The pickleball paddle of claim 7, wherein the external applique comprises an external applique material chosen from a polymeric material, a carbon fiber composite material, or a metallic material.

10. A pickleball paddle, comprising:a head comprising:a front striking surface;a rear striking surface opposite the front striking surface; anda core between the front striking surface and the rear striking surface;a frame coupled to the head, comprising:a frame top edge;a first frame lateral edge;a second frame lateral edge;a handle having a handle upper end, a handle butt end opposite the handle upper end, and a handle body extending between the handle upper end and the handle butt end; anda throat defining a transition between the first and second frame lateral edges and the handle, the throat comprising:a first throat arm adjacent the first frame lateral edge;a second throat arm adjacent the second frame lateral edge;a throat stem adjacent the handle upper end;a throat junction joining the first throat arm, the second throat arm, and the throat stem; anda throat internal surface defining a throat internal cavity;wherein the first throat arm, the second throat arm, and the throat stem are oriented in a substantially Y-shape; andDocket No. KMC-25-006-PCTa stiffness modifying structure disposed within the throat internal cavity and extending into the first throat arm, the second throat arm, the throat stem, and the throat junction.

11. The pickleball paddle of claim 10, wherein the stiffness modifying structure comprises multiple, mating stiffness structure components.

12. The pickleball paddle of claim 10, wherein the stiffness modifying structure comprises an internal goblet throat stiffener comprising:a first stiffener arm extending into the first throat arm; a second stiffener arm extending into the second throat arm;anda lower extension defining a cavity configured to receive part of the head;wherein the internal goblet throat stiffener is in contact with the throat internal surface.

13. The pickleball paddle of claim 12, wherein each of the first stiffener arm and the second stiffener arm comprises a c-channel cross section.

14. The pickleball paddle of claim 12, wherein the internal goblet throat stiffener comprises a carbon fiber composite, a metallic alloy, or a fiber-filled thermoplastic.

15. The pickleball paddle of claim 12, wherein the internal goblet throat stiffener has a mass between 0.5 grams and 25.0 grams.

16. A pickleball paddle, comprising:a head comprising:a front striking surface;a rear striking surface opposite the front striking surface; andDocket No. KMC-25-006-PCTa core between the front striking surface and the rear striking surface;a frame coupled to the head, comprising:a frame top edge;a first frame lateral edge;a second frame lateral edge;a handle having a handle upper end, a handle butt end opposite the handle upper end, and a handle body extending between the handle upper end and the handle butt end; anda throat defining a transition between the first and second frame lateral edges and the handle, the throat comprising:a first throat arm adjacent the first frame lateral edge;a second throat arm adjacent the second frame lateral edge;a throat stem adjacent the handle upper end;a throat junction joining the first throat arm, the second throat arm, and the throat stem; anda throat internal surface defining a throat internal cavity;wherein the first throat arm, the second throat arm, and the throat stem are oriented in a substantially Y-shape; anda stiffness modifying structure, comprising:a first internal stiffener disposed within the throat internal cavity in the first throat arm; anda second internal stiffener disposed within the throat internal cavity in the second throat arm;wherein each of the first and second internal stiffeners comprises a plurality of through apertures.Docket No. KMC-25-006-PCT17. The pickleball paddle of claim 16, wherein each of the first and second internal stiffeners comprises between 2 and 25 through apertures.

18. The pickleball paddle of claim 16, wherein each through aperture of the plurality of through apertures has a generally circular cross section.

19. The pickleball paddle of claim 16, wherein each of the first and second internal stiffeners has a mass between 0.5 grams and 25.0 grams.

20. The pickleball paddle of claim 16, wherein each of the first and second internal stiffeners comprises a thermoplastic polymer, a vitrimeric polymer, a metallic alloy, or a fiber-reinforced composite.

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