WO2025090772A1

WO2025090772A1 - Sport game paddle

Info

Publication number: WO2025090772A1
Application number: PCT/US2024/052822
Authority: WO
Inventors: Nathaniel Joel Radcliffe
Original assignee: Conceptr Partners LLC
Current assignee: Conceptr Partners LLC
Priority date: 2023-10-25
Filing date: 2024-10-24
Publication date: 2025-05-01
Anticipated expiration: 2026-04-25

Abstract

A sport game paddle, in accordance with the present disclosure, includes a head comprising a head thickness and including a front faceplate and a back faceplate, each of the front faceplate and the back faceplate have a concave striking surface defined by a continuous curvature. A handle is connected to the head. A frame defines a perimeter of the sport game paddle. The frame includes a head section extending about the head, a handle section extending along the handle, and a transition section joining the head section and the handle section. The head section and the handle section comprise a first frame thickness and the transition section comprises a rib comprising a second frame thickness. The second frame thickness being greater than each of the first frame thickness and the head thickness. The rib is operable to oppose bending and twisting of the head relative to the handle.

Description

SPORT GAME PADDLE

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application is a non-provisional patent application claiming priority to U.S. Provisional Patent Application Ser. No. 63/592,925 filed on October 25, 2023, and entitled “Pickleball Paddle with Geometric Features that Improve Acoustics and Performance,” the full disclosure which is hereby incorporated by reference in its entirety.

BACKGROUND

[0002] The present disclosure relates to a paddle for sport games such as pickleball, padel, or the like that provides a uniquely designed concave faceplate and an improved structural transition section in the “throat” transition region connecting a head and a handle thereof.

Description of the Related Art

[0003] Pickleball is a versatile and rapidly growing sport played on a badminton-sized court with a 34-inch net. It uses plastic balls and paddles made from a variety of different materials, making it suitable for indoor or outdoor play. The game is beginner- friendly yet can be highly competitive. The game's social and multi-generational appeal has garnered a passionate following. Pickleball can be played as singles or doubles, with easy-to-learn rules, minimal attire requirements, and affordable, portable equipment. Popular in schools and adult communities, pickleball is governed by USA Pickleball (USAPickleball.org).

[0004] Pickleball and other paddle sport players are often in pursuit of paddle designs that improve impact sound, feel, performance, forgiveness of mishits, and paddle durability with the ability to be customized to suit their preferences. Paddles are typically manufactured using multiple materials, layers, and components that may include wood, metal, fiberglass, carbon fiber composites, foam, plastic, rubber, and resin. Manufacturing methods can include layered bonding, thermoforming, injection molding, CNC machining, bladder molding, grinding, polishing, painting, decoration, assembly, and combinations thereof.

[0005] The behavior of the pickleball ball after impact with the pickleball paddle is generally defined by the speed, orientation, and path of the paddle along with the structural, mass, and surface properties of the paddle.

[0006] In recent years, pickleball has garnered attention due to noise issues, primarily stemming from the sound produced when the paddle impacts the ball. In many communities, disputes exist between pickleball players and residents near pickleball courts. In some communities, pickleball courts have been closed due to noise complaints.

[0007] Further, pickleball “shots” (contact between a paddle and a pickleball) are often hit off-center due to skill level, the speed of the game, and the relative size of the head of the paddle when compared to a tennis racquet and a ball of similar size. “Center” can be defined by the center of gravity or center of percussion of the paddle or a considered combination thereof. A paddle’s center of gravity is the center of mass distribution for a paddle, whereas a paddle’s center of percussion is dictated by the geometry and vibrational response of the paddle. Head rotation on off-center impacts is generally related to the paddle’s center of gravity, mass properties, the distance from the impact to the center of gravity of the paddle, and the resistance to twisting and deflection that the player can provide while the ball is in contact with the paddle.

[0008] FIG 1. Illustrates a conventional example of a complete pickleball paddle 10. The pickleball paddle 10 generally includes a handle section 20 and a head section 12. The handle 20 generally includes a flared section at a butt end 22. In this case, a handle form 22 is mounted to the handle 20 section of the paddle 10. The head 12 is generally composed of an inner core 18 with a faceplate surface 16 on opposite sides of the head 12. The core 18 can be formed from a polymeric honeycomb material, however, the core can be made from other alternative materials. A transition area or throat 14 exists between substantially parallel sides 24 of the head 12 and handle 20 that may or may not include a protective edge guard mounted around the perimeter. The perimeter of the paddle is defined as the outer edge and side wall of the face plate and excludes the edge guard that may or may not be present on a paddle 10. The throat 14 is considered to be the weakest structural region of a conventional pickleball paddle 10.

[0009] U.S. Patent No. 11,597,169 B2 by Simmons describes a pickleball paddle and method of making the same. As part of the method for manufacturing a paddle, Simmons discloses a plastic or composite molded material wrapped around a tubular bladder or center and placed in a mold to form a paddle frame. In some embodiments, additional composite material is wrapped at specific positions on the frame to tune the balance point and rebound characteristics of the finished paddle. While Simmons discloses methods for manufacturing a paddle with an internal frame, the design and method of manufacturing are disadvantageous for several reasons. First, both methods of manufacturing require the frame or paddle to be removed from the mold before mounting the front and rear shells. This requires adding several steps to the manufacturing process and reduces the structural integrity of a unitary paddle design.

[0010] Secondly, Simmons discusses adding additional composite material to specific positions on the frame to tune the balance point and rebound characteristics of the finished paddle.

[0011] U.S. Patent No. 5,150,896 by Holmes describes a game racket 20 having rigid, incurvature contact surfaces 29 with an open network 26 for the passage of air in place of the conventional network of strings, and ovoid strips 27 provided in a cross-section pattern. This game racket 20 is a tennis racket, wherein the plurality of open network 26 is provided to decrease the weight of the racket 20. However, this design by Holmes is disadvantageous to paddle design as the surface contains apertures that weaken the structural integrity of the paddle, reduce contact surface area on impacts with the ball, create an inconsistent reflection of impacts, produce a paddle with excessive total weight, turbulent airflow/whistling, and a less pleasant impact sound and feel when compared to this invention. Additionally, Holmes’ design may not conform to the rules of several paddle sports. In fact, according to USA pickleball rules, the impact surface is required to be rigid, smooth and not containing holes or apertures, indentations, or excessive rough texturing.

SUMMARY

[0012] The present disclosure provides a sport game paddle that significantly improves upon existing designs. The sport game paddle of the present disclosure features a head having a concave striking surface defined by a continuous curvature and a frame defining a perimeter of the sport game paddle that cooperate to improve the acoustic and game performance characteristics of the paddle.

[0013] In one aspect, the sport game paddle of the present disclosure improves acoustic performance by producing a sound upon impacting the ball that is less disruptive to both the players and the local community.

[0014] In another aspect, the sport game paddle of the present disclosure provides good control, energy return, impact feel, and off-center performance while allowing the player to impart the desired speed, direction, spin rate, and spin axis on different types of shots. In this regard the sport game paddle of the present disclosure helps minimize inaccuracies associated with off-center impacts between the paddle and the ball and/or improves the trajectory of the ball when the ball is mishit.

[0015] In still a further aspect of the sport game paddle of the present disclosure, the structure of the paddle is strengthened, particularly at a transition between the head and the handle of the paddle. [0016] Additional features and utilities of the present disclosure will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] These and/or other features and utilities of the present disclosure will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:

[0018] FIG. 1 illustrates a conventional pickleball paddle, according to the prior art;

[0019] FIG. 2A illustrates a perspective view of a sport game paddle according to the present disclosure;

[0020] FIG. 2B illustrates a front view of the sport game paddle of FIG. 2A, according to the present disclosure;

[0021] FIG. 2C illustrates a side view of the sport game paddle of FIG. 2A, according to the present disclosure;

[0022] FIG. 2D illustrates a perspective view of an internal frame of the sport game paddle according to the present disclosure;

[0023] FIG. 2E illustrates a top view of the sport game paddle according to the present disclosure;

[0024] FIG. 2F illustrates cross-sectional views from top to bottom (A-A) and side to side (B- B) of the sport game paddle according to the present disclosure;

[0025] FIG. 3A illustrates a perspective view of an internal frame of the sport game paddle of FIG. 2A, according to the present disclosure;

[0026] FIG. 3B illustrates a perspective view of an inner foam gasket of the sport game paddle of FIG. 2A, according to the present disclosure;

[0027] FIG. 3C illustrates a front view of an exemplary concave inner core of the sport game paddle of FIG. 2A, according to the present disclosure;

[0028] FIG. 3D illustrates a side view of the inner concave core of the sport game paddle of FIG. C, according to the present disclosure;

[0029] FIG. 3E illustrates a perspective view of a composite exterior shell of the sport game paddle of FIG. 2A, according to the present disclosure; [0030] FIG. 4 illustrates a perspective view of the sport game paddle according to another example embodiment of the present disclosure;

[0031] FIG. 5A illustrates a front view of the sport game paddle according to another example embodiment of the present disclosure;

[0032] FIG. 5B illustrates a side, cross-sectional view of the sport game paddle of FIG. 5A, according to the present disclosure;

[0033] FIG. 5C illustrates a top, cross-sectional view of the sport game paddle of FIG. 5A, according to the present disclosure;

[0034] FIG. 6A depicts a prior art sport game paddle contacting a ball;

[0035] FIG. 6B depicts a sport game paddle in accordance with the present disclosure contacting a ball;

[0036] FIG. 6C depicts balls hit from the sport game paddle of FIG. 6A and the sport game paddle of FIG. 6B traveling toward a pickleball net;

[0037] FIG. 7 depicts a graphic representation of an acoustic response caused by a ball contacting the sport game paddle of the present disclosure;

[0038] FIG. 8A illustrates a perspective view of a sport game paddle having a concave inner core without a perimetrical frame, in accordance with the present disclosure;

[0039] FIG. 8B is a side view of the sport game paddle of FIG. 8A, in accordance with the present disclosure;

[0040] FIG. 8C illustrates a top view of the sport game paddle of FIG. 8A, in accordance with the present disclosure; and

[0041] FIG. 8D illustrates cross-sectional views from top to bottom (A- A) and side to side (B- B) of the sport game paddle according to the present disclosure.

[0042] The drawings illustrate example embodiments of the present disclosure and are not to be considered limiting in its scope, as the overall disclosure may admit to other equally effective embodiments.

DETAILED DESCRIPTION

[0043] Reference will now be made in detail to the embodiments of the present disclosure, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present disclosure while referring to the figures. Also, while describing the present disclosure, detailed descriptions of related well-known functions or configurations that may diminish the clarity of the points of the present disclosure are omitted.

[0044] It will be understood that although the terms “first” and “second” are used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Thus, a first element could be termed a second element, and similarly, a second element may be termed a first element without departing from the teachings of this disclosure.

[0045] Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list.

[0046] All terms including descriptive or technical terms which are used herein should be construed as having meanings that are obvious to one of ordinary skill in the art. However, the terms may have different meanings according to the intention of the lexicographer, case precedents, or the appearance of new technologies. Also, some terms may be arbitrarily selected by the inventors, and in this case, the meaning of the selected terms will be described in detail in the detailed description herein. Thus, the terms used herein should be defined based on the generally defined meaning of the terms together with the description throughout this specification.

[0047] Hereinafter, one or more exemplary embodiments of the present disclosure will be described in detail with reference to accompanying drawings.

[0048] Example embodiments of the present disclosure are directed to a sport game paddle, that may be used in pickleball (or padel). The paddle exhibits a concave striking surface defined by a continuous curvature and a frame defining a perimeter of the sport game paddle that cooperate to improve the acoustic and game performance characteristics of the paddle. For example, the paddle includes a uniquely designed concave faceplate and an improved structural section in the “throat” or transition region connecting a head and a handle thereof. More specifically, the sport game paddle of the present disclosure provides a striking surface that compensates or corrects for rotation experienced on off-center impacts with a ball and includes a specifically designed structural transition section between the head and handle of the sport game paddle to provide reinforcement therebetween.

[0049] According to one example of the present disclosure, the sport game paddle may be used to play pickleball and is designed to conform to the rules of USA pickleball as it is rigid, non-compressible, and smooth. The sport game paddle’s hitting surface does not contain holes or apertures, indentations, or excessively rough texturing. The design of the present disclosure also applies to a padel racket and a table tennis paddle, as are described in detail below.

[0050] FIG. 2A illustrates a perspective view of a sport game paddle, shown in the form of a sport game paddle 100 according to an example embodiment of the present disclosure, and FIG. 2B illustrates a front view of the pickleball paddle according to the example embodiment of FIG. 2A. Referring to FIGS. 2A and 2B, the sport game paddle 100 according to this example embodiment can include a head 102, a handle 104, and a transition or throat 106. The head 102 includes a concave outer impact faceplate 108 on both a front face 108a and a back face 108b thereof. The term “concave” should be understood to describe a surface that curves inwardly and/or is inwardly arched or bowl-shaped. It is to be noted that the impact faceplate 108 on both the front face 108a and the back face 108b define an outer boundary or head thickness of the head 102 of the sport game paddle 100, according to the present exemplary embodiment, are preferably identical in design. However, it is to be noted that the impact faceplate 108 on the front face and the back face of the head 102 are not limited to being identical in design and can alternatively include a concave design on one of the front face and the back face and a flat face design (or another shape) on the other one of the front face and back face. For simplicity and in order to provide brevity to the detailed description herein, both the front face and the back face of the head 102 will be considered to both include an outer impact faceplate 108 having a concave surface.

[0051] As illustrated by circles and crosshairs drawing that depicts a middle or geometric center of the faceplate 108 of the head 102, the front faceplate 108 can include a concave design such that from the top of the head 102 to the middle of the head 102 and from the bottom of the head 102 to the middle of the head 102 the faceplate 108 will slope inward (or speak to normal vectors with increasing inward angles from the center to the perimeter (see reference number 108a), and from both left and right sides of the head 102 to the middle of the head 102 the faceplate 108 will slope inward (see reference number 108c). With this concave configuration, the head thickness of the head 102 becomes increasingly thinner (front to back) while traversing the head 102 from the outer perimeter towards the middle section thereof. In this example embodiment the head 102 of the paddle 100 has an equally sloped faceplate 108, wherein the geometric center of the head 102 is thinnest. Although FIGS. 2A-2B illustrate where the curvature of the faceplate 108 is equally sloping from the outer perimeter thereof to the center thereof, it is to be noted that in an alternative example embodiment the center of curvature of the faceplate 108 can be moved up or down along a longitudinal axis that extends through handle 104 or can be moved along a lateral axis that is orthogonal to the longitudinal axis. That is the center of curvature of the faceplate 108 may be moved left or right of the longitudinal axis to suit the preferences of each user, or the concave radius can vary from the center to the perimeter in the lateral or longitudinal direction, which may include large radii that approach a surface profile that is flat or nearly flat in a local region. In an example embodiment, the radius of curvature for the longitudinal and lateral direction can be between 500mm and 10000mm, and more preferably between 1000mm and 5000mm. In another example embodiment, the concave radius is not constant in the longitudinal or lateral direction. In still another example embodiment the center of curvature can be shifted longitudinally up or down relative to the geometric center of the impact faceplate 108. Providing a concave faceplate 108 can be accomplished by forming an inner core (described in more detail with reference to FIGS. 3C- 3D) to have an offset or variable concavity thereof. In an example embodiment of the present disclosure, the concave core can be formed of a polymeric honeycomb or other, lightweight structural core wherein the walls are thin, and the overall inner core is light in weight. In another example embodiment the faceplate 108 can have a constant or variable thickness ranging between 0.2mm to 3.0mm.

[0052] FIG. 2C illustrates a side view of the sport game paddle 100 according to the example embodiment of FIG. 2A. With this side view the concavity of the faceplate 108 from the top and bottom of the head 102 to the center of the head 102 can be easily viewed. The same or similar concavity of the faceplate 108 should be understood to be present when viewing the pickleball paddle from top to bottom (not illustrated for brevity of the application and figures).

[0053] With a conventional pickleball paddle 10 as illustrated in FIG. 1, a flat faceplate 16 making contact with a pickleball off-center relative to the center of gravity projection of the paddle will cause horizontal paddle rotation, longitudinal paddle rotation, or a combination thereof to one side or the other resulting in the pickleball leaving the faceplate 16 at an angle different from the intended target direction. However, with the concave faceplate 108 of the present example embodiment as illustrated in FIGS. 2A-2C, each point along the faceplate 108 will progressively change the normal vector direction of the faceplate 108 from the center to the outer perimeter, thus offering a correction for off-center impacts by a pickleball. With the uniquely designed configuration of a concave faceplate 108 for a sport game paddle 100, a user can experience better pickleball direction (launch and azimuth angle) control, better energy return on impact, a more secure impact feel, and better ball speed, spin rate, and spin axis control on different types of shots. It is to be noted that the present disclosure of providing a pickleball paddle with a concave faceplate, as illustrated in FIGS. 2A-2C, equally applies with respect to padel rackets, and therefore padel rackets with the present inventive design as described herein are included as part of the present disclosure.

[0054] Details regarding the formation of the concave shaped faceplate 108 will be described below with reference to FIGS. 3C-3D.

[0055] FIG. 2D illustrates a perspective view of a frame 120 that extends about a perimeter (not separately labeled) of a sport game paddle such as a sport game paddle 100 uniquely formed using a bladder molding or similar process of composite material to form a pickleball paddle according to another example embodiment of the present disclosure. Frame 120 includes a head section 120a that extends about head 102, a handle section 120b that extends along handle 104, and a transition section 120c that joins head section 120a and handle section 12b. According to the example embodiment as illustrated in FIG. 2D, the frame 120 can include a first frame thickness in head section 120a and handle section 120b and, as will be detailed more fully herein, a second frame thickness along portions of transition section 120c. In a non-limiting embodiment, the first frame thickness may define head section 120a while handle section 120b includes a third frame thickness. In such a design case, the second frame thickness is greater than the first frame thickness and the third frame thickness. Further, each of the first frame thickness, the second frame thickness and, if provided, the third frame thickness may be variable along the respective frame sections 120a, 120b, and 120c.

[0056] Sport game paddles typically experience, two low frequency, vibratory modes, one due to the handle 20 bending up/down in one mode and a second side to side in a second mode relative to the head 12. This weakened region causes vibration at impact, audible sound, and can reduce paddle durability, perception of sound and feel, and energy transfer at impact. In order to enhance structural stability, the second frame thickness is defined by thicker/raised ribs 109 that extend along a perimeter of the transition/throat section 120c of the frame 120 extending between the head 102 and the handle 104. These thicker/raised ribs 109 are preferably disposed along the frame 120 in the shape of a “wishbone design” 110 (i.e., extending from the upper end of the handle 104 toward both opposing sides of the head 102). The wishbone configured ribs 110 provides a Y-shaped structural reinforcement to a highly stressed region on both sides of the paddle (the transition/throat section) during use.

[0057] This wishbone configured ribs 110 can be formed by providing an increased cross- sectional height geometry (a raised section relative to the striking face and perimeter) along a length of the transition section 120c (aka: the throat section) of the frame 120 and the mold forming the exterior surface of the paddle. More specifically, the transition section 120c of frame 120 extends between the lower regions of the head section 120a of frame 120 and the upper end of handle section 120b of frame 120. The section of frame 120 extending into the handle 104 can also be configured to form the full profile of the handle with or without additional foam 130 or handle form 104a or (flared) butt end form 104b. The sections of the frame 120 are likely to vary in height, width and cross-section from the handle to the perimeter of the paddle as defined by each design. The surface profile of the primary, external mold defines the final profile of the frame as it is formed to support the external profile of the faceplate(s) perimeter, throat, and handle of the paddle.

[0058] Preferably, the wishbone configured design 110 can be provided on both a front side and a rear side of the paddle frame 120. This raised wishbone design 110 feature as described herein and illustrated in FIG. 2D is configured to increase the cross-sectional height of the transitional section 120c (locally focused at the transition section 120c) and increase the stiffness of the sport game paddle perimeter through the transition section 120c. In addition, with this integrated internal frame 120 (one single piece) having variable cross-sectional dimensions as provided in this example embodiment, the transition section 120c of the sport game paddle 100, the overall structural integrity of the sport game paddle 100, energy transfer, and perceived sound of impact of the sport game paddle 100 can be improved with respect to a conventional pickleball paddle.

[0059] Through finite element analysis including modal analysis and physical acoustic testing, vibratory modes were measured and observed at sequentially higher frequencies on standard pickleball paddles beyond simple translation, rotation and handle vibration models. Many of these vibratory modes are audible and contribute to the signature sound of paddles and specifically pickleball paddles impacting balls. It has also been determined by the present inventor utilizing acoustic and modal analysis that paddles are subject to audible, vibratory twisting modes in addition to more traditional, percussive modes when making contact with a pickleball, which can negatively impact the feel as well as the acoustics of the paddle. Accordingly, the internal frame 120 illustrated in FIG. 2D has been designed to provide additional perimeter support (enhanced cross-sectional area) between the handle 104 and the head 102 of the sport game sport game paddle 100 (see FIGS. 2A-2C). This uniquely structured internal frame 120 is preferably made of a composite, carbon fiber, or fiberglass material or can be made of a polymeric material by way of additive manufacturing.

[0060] FIG. 2E illustrates a top view of sport game paddle 100 according to an example embodiment of the present disclosure. With reference to FIG. 2E, it can be clearly seen how the wishbone design 110 of sport game paddle 100 is raised/thicker at the transition section of the frame 120 as compared to the head section 120a of the frame 120. The wishbone design 110 is formed at both left and right regions of the transition section 106 of the sport game paddle 100 in order to have an increased cross-sectional area throughout the entire transitional section 106.

[0061] FIG. 2F shows cross-sectional views of the sport game paddle 100 described in FIGS 2A-2F from top to bottom (A- A) and side to side (B-B) through the approximate centerline of the paddle. From these views, it is evident that the face plate and core are both concave with the thickness of the sport game paddle 100 being thinner in the center than the top, bottom, left or right side of the perimeter of the head 102 of the sport game paddle 100.

[0062] In the present manufacturing process as described in more detail below with respect to FIGS. 3A-3E, the internal frame 120 is preferably provided in a partially cured, “pre-preg” form wrapped around a polymeric, uninflated bladder to allow easy handling (flexible) thereof while being used to form the entire sport game paddle 100. In other words, the internal frame 120 can be easily manipulated after being placed in a mold for proper positioning with other sport game paddle components, which when simultaneously inflated, compressed, and molded together form the resulting sport game sport game paddle 100. “Pre-preg” is a composite material made from pre-impregnated fibers and a partially cured polymer matrix, such as epoxy or phenolic resin, or even thermoplastic mixed with liquid rubbers or resins.

[0063] A process of manufacturing the sport game paddle 100, according to another example embodiment of the present disclosure, is described below with reference to FIGS. 3A-3E. The resulting sport game paddle 100, manufactured through the process described below, is the same as the sport game paddle 100 illustrated in FIGS. 2A-2F. This process can be performed as a single-step molding process. However, the process of manufacturing a sport game paddle 100 is not limited to using a single-step molding process and can alternatively be performed in two or more molding or manufacturing steps.

[0064] Referring to FIGS. 3A-3B, a preferred manufacturing process for a pickleball paddle according to an example embodiment of the present disclosure utilizes a molding process that fuses several individual components together simultaneously in a single compression molding step. This single compression molding process may utilize a bladder molding process, which is a composite manufacturing technique that involves wrapping sheets of “pre-preg” composite material around an uninflated polymeric disposable bladder (not illustrated). These sheets of impregnated fiber can be wrapped around an inflatable disposable bladder placed inside a mold cavity and subsequently inflated during the molding process. The bladder molding process uses a positive pressure applied to the bladder disposed inside a pre-preg tubular shaped carbon fiber frame 120 to force the bladder and the pre-preg shaped tubular frame 120 against the inside surface of the mold cavity and against the other carbon fiber, foam, or polymeric components, as described in more detail below.

[0065] The carbon fiber pre-preg shaped tubular frame 120 is preferably first wrapped around the uninflated (disposable or reusable) inflatable bladder and is configured to include the raised cross-sectional area forming the wishbone design 110 prior to inflation during the molding process, as described above with reference to FIG. 2D. In forming the entire sport game paddle 100, first, a back side (not illustrated) sheet material (preferably made of carbon fiber) for the head 102 is placed in the mold cavity. Then the pre-preg, shaped tubular frame 120 is wrapped around the uninflated bladder to form an inflatable carbon fiber frame 120 that is placed in the mold cavity over the back side composite shell or faceplate material. Between the carbon fiber frame 120 and core 140 can be placed an expandable foam material 130 formed in the interior profile shape of the frame 120 and external profile of a core 140 (described below). The foam material 130 is configured to maintain the desired resulting shape of the frame 120 and to securely receive an inner core 140 therein, as described below with reference to FIGS. 3C-3D. The foam material 130 can include a head section 130a and a handle section 130b. The foam material 130 may expand to support the interior surfaces of an external, concave faceplate.

[0066] Referring to FIGS. 3C-3D, a core 140 is manufactured to have a concave shape on both opposing faces thereof and is placed over the back side sheet or faceplate material and within the head region 130a of the foam material 130 (also within a head region of the mold cavity). The core 140 is preferably formed of a polymeric honeycomb material or other lightweight structural core, providing a thin-walled, lightweight internal body for the head. Then a front side (not illustrated) sheet or faceplate material (preferably made of carbon fiber or composite) for the head 102 of the sport game paddle 100 can be placed over the core 140 and outside the perimeter of the head region 130a of the foam material 130 and frame 120 (also within a head region of the mold cavity). A handle wrap material can be wrapped around a handle section 120b of frame 120 formed from the carbon fiber pre-preg material. The back side sheet or faceplate material, front side sheet or faceplate material, and handle wrap material can be tucked around the respective outer perimeter region of the frame 120 formed from carbon fiber pre-preg material to provide a smooth outer perimeter of sport game paddle 100.

[0067] The mold cavity can then be placed into a high heat chamber (not illustrated for brevity of the application) while the inflatable carbon fiber frame 120 is inflated with air to reinforce the desired resulting shape of the finished frame of the sport game paddle 100. After the entire set of components within the mold cavity are properly laid out, properly tucked, and heated under compressive pressure for a predetermined period of time while the carbon fiber frame 120 is simultaneously inflated, the resulting sport game paddle 100 is completely manufactured in a single step to form a unitary composite shell for a sport game paddle 100.

[0068] Although the frame 120, the back face sheet or faceplate material, the front face sheet or faceplate material and the external handle wrap material were described as being formed of a carbon fiber material, each of these components can alternatively be formed of other materials including foam, plastics, polymers, natural materials, metals, adhesives, fabrics, or other compositions, without departing from the spirit and scope of the overall present disclosure.

[0069] The carbon fiber (or pre-preg) material of the frame 120, back faceplate sheet material, front faceplate sheet material and handle wrap material are each only partially cured as “prepreg” before being placed into a mold cavity in order to allow flexibility and ease of handling thereof, which enables the components to be manipulated and wrapped around the outer perimeter of the frame 120 within the mold to obtain the desired placement of each of the components before heat and pressure are applied to form a unitary pickleball paddle in a single or multi-step molding process, according to example embodiments of the present disclosure.

[0070] FIG. 3E illustrates the geometry of the composite shell of a completely manufactured sport game paddle 100 after being pressurized, heated, and removed from the mold cavity. At this time a handle form 104a can be applied to the handle 104 and a flared butt cap 104b (see FIG. 2A) can be applied to the end of the frame handle 104a. Alternatively, the handle profile can be formed in the molding process by expanding the handle portion of the frame 102b to create the desired handle profile.

[0071] FIG. 4 illustrates a sport game paddle 200 according to another exemplary embodiment of the present disclosure. In this exemplary embodiment the entire sport game paddle 200 can be manufactured exactly as, or similar to that described with reference to FIGS. 3A-3D, with the exception of using the concave core. In this example embodiment the core is not concave but instead can have flat outer faces, as commonly used with conventional paddles. As illustrated in FIG. 4, a wishbone design 210 is provided at a transition section 206 of the head section 202, while a flat faceplate 208 is provided. The handle section 204 and the transition section 206 are provided the same as the sport game paddle 100 as described with reference to FIGS. 2A-2D.

[0072] FIG. 5A illustrates a front view of a sport game paddle shown in the form of a padel racket 500 according to another exemplary embodiment of the present disclosure. The padel racket 500 includes a commonly shaped head section 502, a commonly shaped handle section 504 and a commonly shaped transition section 506 extending between a lower area of the head section 502 and an upper end of the handle section 504. A front faceplate 508 can include a concave design such that from the top of the head section 502 to the middle of the head section 502 and from the bottom of the head section 502 to the middle of the head section 502 the faceplate 508 will slope inward (see reference number 508a), and from both left and right sides of the head section 502 to the middle of the head section 502 the faceplate 508 will slope inward (see reference number 508b). With this concave shaped configuration, the thickness of the head section 502 becomes increasingly thinner (front to back) while traversing the head section 502 from the outer perimeter towards the middle section thereof. In this example embodiment the head section 502 of the padel paddle 500 has an equally sloped faceplate 508, wherein the absolute center of the head section 502 is thinnest. Although FIG. 5A illustrates where the curvature of the faceplate 508 is equally sloping from the outer perimeter thereof to the center thereof, it is to be noted that in an alternative example embodiment, the center of curvature of the faceplate 508 can be moved up or down longitudinally or can be moved left or right horizontally to suit the preferences of each user. This can be accomplished by forming an inner polymeric honeycomb core to have an offset concavity thereof. Additionally, the concave faceplate(s) and supporting concave core may also have a variable horizontal or longitudinal radius from the center to the perimeter of the paddle. The variable radius may include local regions that are substantially flat.

[0073] FIG. 5B illustrates a side cross-section view of the padel paddle 500 according to the example embodiment of FIG. 5A. As illustrated and referenced by the cross-sectional view A-A, both the front and back faceplates 508 are concaved inward from the top and bottom perimeters towards the center thereof.

[0074] FIG. 5C illustrates a top cross-section view of the padel paddle according to the example embodiment of FIG. 5A. As illustrated and referenced by the cross-sectional view B-B, both the front and back faceplates 108 are concaved inward from the left and right perimeters towards the center thereof.

[0075] As discussed herein, the shape of faceplate 108 will progressively change the normal vector direction of a struck ball. For example, as shown in FIG. 6A, a ball struck approximately 40-mm below the center of a conventional paddle may have a launch angle of about -3.4°. Conversely, a ball struck approximately 40-mm below the center of sport game paddle 100 in accordance with the present disclosure may have a launch angle of about -2.0° as shown in FIG. 6B. This 1.4° reduction in launch angle may be the difference between hitting a net as shown in FIG. 6C and clearing the net. In addition, the addition of the wishbone ribs 110 in cooperation with other paddle features imparts a stiffness to sport game paddle 110 that results in a selected audible sound when subjected to a moderate impact by a ball. The term “moderate impact” should be understood to describe an impact from a ball traveling at between 10 MPH (16.9 KPH) and about 15 MPH (24.14 KPH). As represented in FIG. 7, the selected audible sound for a number of impacts of a typical pickleball and the sport game paddle of the present disclosure depicted in FIG. 2A may be represented by an audible signal having a maximum magnitude, audible frequency of about 1,499 Hz and an average power level of about 78.0 dBa and a peak power level of about 92.6 dBa perceived within about 2 feet (0.609-meters) of the impact. With each sport game paddle of the present disclosure, impact location, and impact condition, this frequency and sound measurement may vary. The primary frequency of the sport game paddle depicted in FIG. 2A will typically be greater than conventional sport game paddles.

[0076] In addition to the previously discussed sport game paddles, a frameless sport game paddle 100 is also contemplated such as shown in FIGS, 8A, 8B, 8C, and 8D. Frameless sport game paddle 100 illustrates a perspective view of a sport game paddle, shown in the form of a sport game paddle include a head 102 and a handle 104. The head 102 includes a concave outer impact faceplate 108 on both a front face 108a and a back face 108b thereof. It is to be noted that the impact faceplate 108 on both the front face 108a and the back face 108b define an outer boundary or head thickness of the head 102 of the frameless sport game paddle 100, according to the present exemplary embodiment, are preferably identical in design. In this non-limiting example, frameless sport game paddle 100 includes all the benefits of the concave face surfaces without the added weight of the frame.

[0077] The design of the sport game paddle, in accordance with the present disclosure, presents a uniquely designed configuration of a concave faceplate that allows a user to experience better pickleball direction (launch and azimuth angle) control, better energy return on impact, a more secure impact feel, and better ball speed spin rate and spin axis control on different types of shots. Further, the design of the sport game paddle, in accordance with the present disclosure, produces a higher frequency sound (indicative of a stiffer primary mode) than produced by conventional paddles. The higher frequency sound results in a lower amplitude sound having a rapid decay that is perceived more as a “click” than a “pop” produced by conventional paddles. [0078] The terms “a” and “an” do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. The term “or” means “and/or” unless clearly indicated otherwise by context. Reference throughout the specification to “an aspect”, means that a particular element (e.g., feature, structure, step, or characteristic) described in connection with the aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various aspects.

[0079] The term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ± 8% of a given value.

[0080] Although a few embodiments of the present disclosure have been shown and described, it will be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the disclosure, the scope of which is defined in the appended claims and their equivalents.

Claims

CLAIMS What is claimed is:

1. A sport game paddle, comprising: a head comprising a head thickness and including a front faceplate and a back faceplate, each of the front faceplate and the back faceplate having a concave striking surface defined by a continuous curvature; a handle connected to the head; and a frame defining a perimeter of the sport game paddle, the frame including a head section extending about the head, a handle section extending along the handle, and a transition section joining the head section and the handle section, the head section and the handle section comprising a first frame thickness and the transition section comprising a rib comprising a second frame thickness, the second frame thickness being greater than each of the first frame thickness and the head thickness, wherein the rib is operable to oppose bending and twisting of the head relative to the handle.

2. A sport game paddle, comprising: a head comprising a head thickness and including a front faceplate and a back faceplate, each of the front faceplate and the back faceplate having a concave striking surface including a continuous curvature, the head including a longitudinal axis and a lateral axis that is orthogonal to the longitudinal axis.

3. The sport game paddle according to claim 2, further comprising a structural core disposed between the front faceplate and the back faceplate, the structural core having a core thickness that decreases in size from an outer perimeter of the head toward a center of the head along at least one of the longitudinal axis and the lateral axis.

4. The sport game paddle according to claim 2, further comprising a structural core disposed between the front faceplate and the back faceplate, the structural core having a core thickness that decreases in size from an outer perimeter of the head toward a center of the head, the core thickness having one of a constant radius and a progressive parabolic radius.

5. The sport game paddle according to claim 2, wherein the head includes a geometric center, the continuous curvature including a center of curvature that is off-set relative to the geometric center of the head.

6 The sport game paddle according to claim 2, wherein the center of curvature is off-set from the geometric center of the head along the longitudinal axis.

7. The sport game paddle according to claim 2, wherein the head section includes a geometric center, the head thickness at a perimeter of the head being greater than the head thickness at the geometric center.

8. The sport game paddle according to claim 2, wherein the continuous curvature includes a variable concave radius over at least one of the longitudinal axis and the lateral axis.

9. The sport game paddle according to claim 1, wherein the sport game paddle defines a pickleball paddle.

10. The sport game paddle according to claim 1, wherein the front faceplate and the back faceplate together define, in part, a unitary composite shell formed from a carbon composite material.

11. A sport game paddle, comprising: a head comprising a head thickness and including a front faceplate and a back faceplate; a handle connected to the head; and a frame defining a perimeter of the sport game paddle, the frame including a head section extending about the head, a handle section extending along the handle, and a transition section joining the head section and the handle section, the head section and the handle section comprising a first frame thickness and the transition section comprising a rib comprising a second frame thickness, wherein the rib is operable to oppose bending and twisting of the head relative to the handle.

12. The sport game paddle according to claim 11, wherein the sport game paddle includes a front side and a back side that is opposite the front side, the transition section including a first rib and a second rib on the front side and a third rib and a fourth rib on the back side, the first rib, the second rib, the third rib, and the fourth rib together being operable to provide reinforcement support against bending and twisting of the head section with respect to the handle section.

13. The sport game paddle according to claim 12, wherein the first rib and the second rib form a wishbone design.

14. The sport game paddle according to claim 13, wherein the wishbone design establishes a stiffness of the frame that, when exposed to a moderate impact from a ball, produces a selected audio output.

15. The sport game paddle according to claim 14, wherein the selected audio output has a frequency of about 1,499 Hz.

16. The sport game paddle according to claim 14, wherein the selected audio output has an average power level of about 78.0 dBa and a peak power level of about 92.6 dBa perceived within about 2 feet (0.609-meters) of the moderate impact.

17. The sport game paddle according to claim 14, wherein the moderate impact is produced by a ball traveling at between 10 MPH (16.9 KPH) and about 15 MPH (24.14 KPH) contacting one of the front faceplate and back faceplate.

18. The sport game paddle according to claim 11, wherein the paddle is configured as a padel racket.

19. The sport game paddle according to claim 11, wherein the paddle is configured as a pickleball paddle.

20. The sport game paddle according to claim 11, wherein the front faceplate and the back faceplate together define, in part, a unitary composite shell.