Pickleball Racket PMI Core Mold Structure
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Solution Overview
Problem
Existing pickleball rackets with enhanced shock absorption effects are heavy, difficult to control, and not suitable for users with lower swing power, such as children and the elderly. Additionally, the production cost and complexity of honeycomb-shaped core layers are high.
Innovation Solution
A manufacturing method and structure for a pickleball racket using a core mold made of PolyMethyl MethAcrylate (PMI) material, which eliminates the need for a honeycomb structure and reduces manufacturing costs. The method involves resin impregnation, core wrapping, heating and pressurizing, cooling and curing, and finished product molding to produce a lightweight racket with improved control and shock absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If shock absorption effect is enhanced by using rubber material layers, then impact force absorption improves, but racket weight increases and maneuverability deteriorates
Solution Approach 1:
The patent changes the material parameter from traditional rubber to PMI (poly methyl methacrylimide), which has different physical properties including lower density and higher strength-to-weight ratio, thereby reducing weight while maintaining shock absorption capabilities
Solution Approach 2:
The patent uses a composite structure combining PMI material with elastic material layers, where the PMI provides structural strength and reduced weight, while the elastic layers provide shock absorption, achieving both lightweight construction and impact protection
2Object-affected harmful factors
If honeycomb structure is used for shock absorption, then impact force buffering improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the honeycomb structure from the core mold and replaces it with a solid PMI core, eliminating the complex honeycomb formation process while maintaining the shock absorption function through the elastic material layers applied to the core surface
Solution Approach 2:
The patent uses a disposable core mold made of PMI material that is inexpensive to manufacture and simple in structure, replacing complex reusable honeycomb structures, thereby reducing manufacturing cost and complexity
3Object-affected harmful factors
If shock absorption layers are added to racket face, then rebound sensitivity decreases, but face strength and hardness are reduced
Solution Approach 1:
The patent applies elastic material layers locally on the striking surface of the PMI core, providing shock absorption only where needed for impact absorption, while the rest of the PMI structure maintains its full strength and rigidity for structural support
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The PMI core mold provides higher strength and rigidity, resulting in better rebound elasticity and improved control feel, while reducing the overall racket weight and manufacturing costs. This makes the racket suitable for users with lower swing power and enhances the overall playing experience.
Implementation Method 1
heating the mold to a predetermined temperature, the core mold expanding due to heating, creating internal pressure within the semi-finished product
Implementation Method 2
an elastomer layer (20'), made of plastic material, covering the two striking surfaces of the striking portion (11)... achieving shock absorption through the elastomer layer (20')
Data Source
AI summary
A method for manufacturing a pickleball racket includes the following steps: (a) impregnating a composite material with resin; (b) wrapping a core mold, made of PolyMethylMethAcrylimide (PMI), with at least one location to form an elastic layer; wrapping the composite material around the elastic layer and the core mold to form a composite material layer, to form a semi-finished product; (c) placing the semi-finished product into a mold and heating the mold to a predetermined temperature to form internal pressure within the semi-finished product; (d) stopping heating and cooling the semi-finished product to solidify it; (e) removing a pickleball racket from the mold. The pickleball racket forms an integral structure in the order of a core mold, an elastomer layer, and a composite material layer. The pickleball racket is light in weight and has strength and rigidity. The striking surfaces of the pickle racket has hitting elasticity, and shock absorption.