WO2022217045A1 - Raquettes composites et procédés de formation associés - Google Patents

Raquettes composites et procédés de formation associés Download PDF

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Publication number
WO2022217045A1
WO2022217045A1 PCT/US2022/024013 US2022024013W WO2022217045A1 WO 2022217045 A1 WO2022217045 A1 WO 2022217045A1 US 2022024013 W US2022024013 W US 2022024013W WO 2022217045 A1 WO2022217045 A1 WO 2022217045A1
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WO
WIPO (PCT)
Prior art keywords
fabric layer
paddle
layer
core
fabric
Prior art date
Application number
PCT/US2022/024013
Other languages
English (en)
Inventor
Hughes DAVIS
Greta DAVIS
Rockford MACINNES
Original Assignee
Revolin Sports, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Revolin Sports, Llc filed Critical Revolin Sports, Llc
Priority to US18/286,139 priority Critical patent/US20240189679A1/en
Priority to EP22719467.7A priority patent/EP4319893A1/fr
Priority to CN202280041415.6A priority patent/CN117460562A/zh
Publication of WO2022217045A1 publication Critical patent/WO2022217045A1/fr

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Classifications

    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B59/00—Bats, rackets, or the like, not covered by groups A63B49/00 - A63B57/00
    • A63B59/40—Rackets or the like with flat striking surfaces for hitting a ball in the air, e.g. for table tennis
    • A63B59/42—Rackets or the like with flat striking surfaces for hitting a ball in the air, e.g. for table tennis with solid surfaces
    • A63B59/45—Rubber parts thereof; characterised by bonding between a rubber part and the racket body
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B59/00—Bats, rackets, or the like, not covered by groups A63B49/00 - A63B57/00
    • A63B59/40—Rackets or the like with flat striking surfaces for hitting a ball in the air, e.g. for table tennis
    • A63B59/42—Rackets or the like with flat striking surfaces for hitting a ball in the air, e.g. for table tennis with solid surfaces
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B2102/00—Application of clubs, bats, rackets or the like to the sporting activity ; particular sports involving the use of balls and clubs, bats, rackets, or the like
    • A63B2102/08—Paddle tennis, padel tennis or platform tennis
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B2209/00—Characteristics of used materials
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B2209/00—Characteristics of used materials
    • A63B2209/02—Characteristics of used materials with reinforcing fibres, e.g. carbon, polyamide fibres
    • A63B2209/023—Long, oriented fibres, e.g. wound filaments, woven fabrics, mats
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B2209/00—Characteristics of used materials
    • A63B2209/18—Characteristics of used materials biodegradable

Definitions

  • the present teachings pertain generally to composite materials and structures for forming sporting equipment and more specifically to fibrous composites for forming pickleball paddles.
  • the teachings herein are directed to a paddle comprising a striking portion defining a central axis, a handle portion, and a tapered portion contiguous with both the handle portion and the striking portion; a sandwich structure comprising a core layer and a first skin coupled with the core layer, the first skin comprising a first fabric layer and a second fabric layer coupled with the first fabric layer.
  • the paddle may include a substrate interposed between the core layer and the first skin, the substrate configured to facilitate coupling of the core layer and the first skin.
  • the core layer may be a honeycomb structure including one or more cells.
  • the substrate may be a non-woven polymeric fabric, the non-woven polymeric fabric configured to prevent a resin from seeping into the one or more cells of the honeycomb structure.
  • the first fabric layer may be a hemp fabric of between 100 and 170 gsm.
  • the first fabric layer may include a weave pattern that is positioned between -10 degrees and 10 degrees relative to the central axis.
  • the second fabric layer may be a twill flax fabric of between 200 and 300 gsm.
  • the second fabric layer may include a weave pattern positioned at between -10 degrees and 10 degrees relative to the central axis.
  • the first fabric layer may be a bidirectionally woven fabric.
  • the second fabric layer may be a bidirectionally woven fabric positioned at between -5 degrees and 5 degrees, relative to the first fabric layer.
  • the core may comprise a synthetic material.
  • the core may comprise a natural material.
  • the core may comprise an impregnated fiber material.
  • the core may comprise a prepreg laminate material.
  • One or more of the first skin and the second skin may comprise at least six distinct layers stacked in a helical pattern.
  • the core may comprise a dry to the touch material.
  • the core may comprise a tacky material.
  • the core may comprise at least two distinct geometries.
  • the core may comprise a first central geometry that is surrounded by a second perimeter geometry that is different from the first central geometry.
  • the core may comprise a first central geometry that is substantially honeycomb shaped.
  • the core may comprise a first central geometry that is surrounded by a second perimeter geometry, and the second perimeter geometry is substantially gyroid shaped.
  • An additive manufacturing process may form the core.
  • the handle portion may comprise a material that forms the second perimeter geometry.
  • the core may comprise a spiral shape.
  • the core may comprise a spiral shape and the material for forming the spiral shape increases in thickness as the spiral travels to an outer edge of the paddle. The increase in thickness of the material for forming the spiral is from about 20% to about 40% from a beginning point of the spiral to an end point of the spiral.
  • the core may comprise a plurality of branches formed in accordance with Murray’s law.
  • the core may comprise a cardboard grid including an optional resin coating.
  • the core may comprise a woven composite material. The woven composite may be impregnated with a resin.
  • the first skin may be cured separately from the core layer and may be coupled with the core layer after a curing process.
  • the first skin may be cured with the core layer such that the first skin and the core layer are coupled via a cure process.
  • the first skin and a second skin may be formed of the same materials.
  • the first skin and a second skin may be formed of different materials.
  • a nonwoven substrate may be located between the first skin and the core layer.
  • a nonwoven substrate may be located between a second skin and the core layer.
  • the nonwoven substrate may comprise a polymeric material.
  • the nonwoven substrate may comprise a polypropylene or polyester material.
  • the nonwoven substrate may be coupled to the core layer by a hot melt adhesive, and adhesive film, an adhesive resin, or some combination thereof.
  • the first fabric layer, the second fabric layer or both may be fabrics that are impregnated with a resin selected from epoxy resin, polyester resin, vinyl ester resin, phenolic resin, bio resin, thermoplastic resin, or any combination thereof.
  • the first fabric layer, the second fabric layer, or both may be formed of fibers pre-impregnated with resin.
  • the first fabric layer, the second fabric layer, or both may comprise a fiber mat, a cloth, or some combination thereof.
  • the first fabric layer, the second fabric layer, or both may comprise a plain weave hemp having a density of at least about 120 g/cm 2 , but less than about 150 g/cm 2 .
  • the first fabric layer, the second fabric layer, or both may include a unidirectional weave.
  • the first fabric layer, the second fabric layer, or both may include a bidirectional weave having threads extending in a first x-direction and having threads extending in a first y-direction.
  • the first fabric layer, the second fabric layer, or both include a +45/-45-degree weave, where the first x-direction is substantially perpendicular to the first y-direction.
  • the first fabric layer, the second fabric layer, or both may include a 90/0-degree weave.
  • the teachings herein are further directed to a paddle comprising a first composite skin comprising a first fabric layer having a bidirectional weave and formed of a flax fiber and a second fabric layer having a bidirectional weave and formed of a hemp fiber; a second composite skin comprising a third fabric layer having a bidirectional weave and formed of a flax fiber and a fourth fabric layer having a bidirectional weave and formed of a hemp fiber; and a honeycomb core structure interposed between the first composite skin and the second composite skin.
  • the first fabric layer may be outward facing such that the second fabric layer is interposed between the first fabric layer and the honeycomb core structure.
  • the third fabric layer may be outward facing such that the fourth fabric layer is interposed between third fabric layer and the core structure.
  • the paddle may include a striking portion and a handle portion, the striking portion and the handle portion defining a central axis such that the striking portion and the handle are symmetrical about the central axis, the striking portion comprising a leading edge positioned opposite to the handle portion and perpendicular to the central axis.
  • the first fabric layer may be positioned such that at least one of the first x-direction and the first y-direction is positioned within 10 degrees of parallel with the central axis.
  • the third fabric layer may be positioned such that at least one of the third x-direction and the y-direction is positioned within 10 degrees of parallel with the central axis.
  • the second fabric layer may be positioned such that at least one of the second x-direction and the second y-direction is positioned within 10 degrees of parallel with the central axis.
  • the fourth fabric layer may be positioned such that at least one of the fourth x-direction and the fourth y-direction is positioned within 10 degrees of parallel with the central axis.
  • the paddle may include an edge guard positioned about a perimeter of the striking portion.
  • the paddle may include a second edge positioned parallel with the central axis.
  • the paddle may include a third edge positioned parallel with the central axis.
  • All of the first fabric layer, the second fabric layer, the third fabric layer, and the fourth fabric layer may be prepreg sheets.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may be fabrics that are impregnated with a resin selected from epoxy resin, polyester resin, vinyl ester resin, phenolic resin, bio resin, thermoplastic resin, or any combination thereof.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof are formed of fibers preimpregnated with resin.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may comprise a fiber mat, a cloth, or some combination thereof.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may comprise a plain weave hemp having a density of at least about 120 g/cm 2 , but less than about 150 g/cm 2 .
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may include a unidirectional weave.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may include a bidirectional weave having threads extending in a first x-direction and having threads extending in a first y-direction.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may include a +45/-45-degree weave, where the first x-direction is substantially perpendicular to the first y-direction.
  • the first fabric layer, the second fabric layer, the third fabric layer, the fourth fabric layer or any combination thereof may include a 90/0-degree weave.
  • the teachings herein also envision a composite structure for forming a paddle comprising at least two layers of about 200gsm twill woven natural fiber fabric, a resin impregnated in the fabric, and a honeycomb core adhered to the at least two layers via the resin.
  • the teachings herein are further directed to a composite structure for forming a paddle comprising at least one first layer of bi-axial natural fiber fabric having a fiber orientation of ⁇ 45° and - 45° or +/-30 o or +/-60 o , at least one second layer of unidirectional natural fiber fabric having a fiber orientation of 0° or 90° : and a resin material located in direct contact with one or both of the first or second layer,
  • the teachings herein are also directed to a method for forming a laminate for forming a paddle comprising laying up at least three layers of woven hemp mixed with about 30% to about 50% resin content by weight and compressing the three layers using a compression molding machine to form a laminate,
  • the teachings herein further envision a composite structure for forming a paddle comprising at least one layer of woven natural fiber fabrics with a fiber orientation of 0 C and 90° and a thermoplastic resin selected from polypropylene, polylactlc acid, or combinations thereof impregnated in the at least one layer of woven natural fiber fabrics,
  • the composite structure may include a core which may be a honeycomb core located adjacent the first layer, the second layer, or both.
  • the teachings herein are further directed to a sandwich panel comprising a first composite skin comprising a first fabric layer having flax fibers, the first fabric layer having an areal weight of between 200 and 300 grams per square meter, inclusive, and a second fabric layer having hemp fibers, the second fabric having an areal weight of between 100 and 200 grams per square meter, inclusive; a second composite skin comprising a third fabric layer having flax fibers, the third fabric layer having an areal weight of between 200 and 300 grams per square meter, inclusive and a fourth fabric layer having hemp fibers, the fourth fabric having an areal weight of between 100 and 200 grams per square meter, inclusive.
  • the sandwich panel may include a core structure interposed between and coupled to both the first composite skin and the second composite skin
  • the first fabric layer may include a bidirectional weave having first warp threads and first weft threads.
  • the second fabric layer may include a bidirectional weave having second warp threads and second weft threads.
  • the first fabric layer may be coupled to the second fabric layer such the one of the first warp threads and the first weft threads is within five degrees of parallel with the second warp threads.
  • the first composite skin may be coupled to a first side of the panel such that the second fabric layer is interposed between the first fabric layer and the honeycomb panel.
  • the second composite skin may be coupled to a second side of the core structure such that the fourth fabric layer is interposed between third fabric layer and the honeycomb core structure, the second side of the core structure being opposite the first side of the core structure.
  • the paddle may include a striking portion and a handle portion, the striking portion and the handle portion defining a central axis such that the striking portion and the handle are symmetrical about the central axis.
  • the first fabric layer may be formed of a bidirectional weave and includes first warp threads and first weft threads.
  • the third fabric layer may be formed of a bidirectional weave and includes third warp threads and third weft threads.
  • the first fabric layer may be positioned such that at least one of the first warp threads and the first weft threads is positioned within 10 degrees of parallel with the central axis.
  • the third fabric layer may be positioned such that at least one of the third warp threads and the third weft threads is positioned within 10 degrees of parallel with the central axis.
  • the first fabric layer may be formed of a unidirectional weave and includes first threads.
  • the third fabric layer may be formed of a unidirectional weave and includes third threads.
  • the first fabric layer may be positioned such that the first threads are positioned within five degrees of parallel with the central axis.
  • the third fabric layer may be positioned such that the third threads are positioned within five degrees of parallel with the central axis.
  • the second fabric layer may be positioned such that at least one of the second x-direction and the second y-direction is positioned within 10 degrees of parallel with the central axis.
  • the fourth fabric layer may be positioned such that at least one of the fourth x-direction and the fourth y-direction is positioned within 10 degrees of parallel with the central axis.
  • the paddle may include an edge guard positioned about a perimeter of the striking portion.
  • the paddle may include a second edge positioned parallel with the central axis.
  • the paddle may include a third edge positioned parallel with the central axis.
  • All of the first fabric layer, the second fabric layer, the third fabric layer, and the fourth fabric layer may be prepreg sheets.
  • the first fabric layer may be a synthetic fiber material and the second fabric layer may be a natural fiber material.
  • the synthetic material may be a recycled carbon fiber, a recycled fiberglass, basalt, recycled ultra-high molecular weight polyethylene (UHMWPE), or some combination thereof.
  • the natural fiber material may be selected from flax or hemp or combinations thereof.
  • the paddle may include a third fabric layer wherein the first fabric layer may be a synthetic fiber, the second fiber layer may be a natural fiber, and the third fiber layer may be a synthetic fiber.
  • the synthetic material may be selected from carbon fiber, basalt, or combinations thereof, and the natural fiber may be selected from flax, hemp, or combinations thereof. Vibrations may be reduced during use of the paddle as compared to a paddle without the natural fiber layer.
  • the core layer may comprise a plurality of walls for forming cavities having differing shapes, sizes and cross sections.
  • the core layer may comprise a plurality of cavities having differing shapes, sizes and cross sections so that the walls and cavities mimic the structure of bird bones.
  • the core layer may comprise a cavity that receives a plurality of equally sized substantially circular components for supporting the cavity.
  • FIG 1. is a perspective view of an exemplary embodiment of a paddle in accordance with the teachings herein.
  • FIG. 2 is a front view of the paddle of FIG. 1.
  • FIG. 3 is a bottom cross-sectional view of the paddle along the line AA of FIG. 2.
  • FIG. 4 is a detailed cut-away view of the front of an exemplary embodiment of a paddle in accordance with the present teachings.
  • FIG. 5 is a detailed cut-away view of the front of an exemplary embodiment of a paddle in accordance with the present teachings.
  • FIG. 6 is a detailed cut-away view of the front of an exemplary embodiment of a paddle in accordance with the present teachings.
  • FIG. 7 is a detailed exploded view of the paddle along line AA of FIG. 2.
  • FIG. 8 is a front view of an exemplary embodiment of a paddle in accordance with the present teachings.
  • FIG. 9 is a detailed cut-away view of the front of the paddle of FIG. 8.
  • FIG.10 is a schematic of an exemplary layered laminate material in accordance with the present teachings.
  • FIG. 11 shows the layered laminate of FIG. 10 during formation of a prepreg using the laminate.
  • FIG. 12 is a perspective view of two paddles having cores of differing geometries alongside an exemplary paddle having a core that includes both differing geometries.
  • FIG. 13A-13D shows the formation of an exemplary paddle having a spiral core.
  • FIGS. 14A-14D shows variations on exemplary paddle cores having a “tree-like” format.
  • FIG. 15 shows exemplary paddle core structures imitating a “bone-like” arrangement.
  • FIG. 16 is a cross sectional view of exemplary sandwich panel core arrangements.
  • FIG. 17 is a perspective view of an exemplary grid core for a paddle.
  • FIG. 18 is a cross sectional view of an exemplary woven material for a paddle core.
  • FIG. 19 is a cross sectional view of exemplary woven materials for a paddle core.
  • FIG. 20 is an exemplary recycling flow chart for use of recycled paddle core materials. Detailed Description
  • a pickleball paddle (e.g., racket, racquet, pickleball paddle, ping pong paddle, etc.) includes a striking portion formed of a sandwich panel having a core structure interposed between two composite laminate layers.
  • the core structure may be formed of a lightweight material, such as foam, a polymeric core, aluminum honeycomb, and polymeric honeycomb.
  • the core structure of a pickleball paddle must be rigid enough such that the pickleball paddle meets the requirements of the International Federation of Pickleball (IFP) and the USA Pickleball Association (USAPA).
  • IFP International Federation of Pickleball
  • USAPA USA Pickleball Association
  • the teachings herein are directed to materials and methods relating for forming a paddle.
  • the paddles described herein may include a core layer and one or more composite skins.
  • the composite skins may be formed of a variety of different natural, synthetic and recycled materials and may preferably be formed of combinations of these materials.
  • the composite skins may be formed using multiple layers (e.g., two layers, three layers, four layers, eight layers, or even more layers). Each of the layers may comprise the same materials. Each of the layers may comprise different materials. The layers may be selected to alternate two or more materials. Each layer in itself may comprise more than one type of material (e.g., more than one type of fiber, or fibers with coatings thereon).
  • the layers may be coated with a resin, impregnated with a resin, or each fiber of a layer may be coated with a resin.
  • the layers may be formed of woven or nonwoven materials.
  • the layers may be formed of fibers having a relatively low glass transition temperature.
  • the fibers and/or the resin may be formed from thermoplastic materials that can be repaired, reformed and/or recycled upon exposure to heat.
  • the resin and/or fibers may be formed of a thermoset or thermosettable material.
  • the resin and/or fibers may include a foam material or a material that is adapted to foam upon exposure to a stimulus.
  • the paddles may utilize resins, adhesives, films, tapes or other similar joining means to form the resulting combination of core layer and composite skins.
  • the process for forming the paddles described herein may include one or more heating, curing, pressing or compressing steps.
  • the composite skins may be formed and cured in a separate step and may then be assembled with a core layer, which may also include a curing step. Curing may occur at ambient temperatures. Curing may occur upon exposure to heat, UV light, microwave, induction heat, or another stimulus.
  • the method of formation may include forming a first and second composite skin by layering one or more layers onto a platen press to form an uncured first and second composite skin assembly.
  • the first composite skin, a core structure, and the second composite skin may be layered to form an uncured sandwich panel assembly.
  • the first composite skin, the core structure, and the second composite skin are layered so that the first composite skin and second composite skin each lie in direct planar contact with the core structure (core layer).
  • a first fabric layer and second fabric layer may form the first composite skin.
  • a fourth fabric layer, and a third fabric layer may form the second composite skin.
  • the uncured composite skins may be enclosed within a vacuum bag.
  • the uncured composite skins may be debulked within the vacuum bag.
  • the uncured and debulked composite skins may then be placed in an autoclave while the uncured composite skins are still positioned within the vacuum bag.
  • the uncured composite skins are cured in the autoclave and then assembled with the core and heated in a platen press.
  • the paddles described herein may be treated and/or formed to develop a desirable texture (e.g., roughness) on the exterior surfaces of the paddle.
  • the texture of the paddle is important for spinning the ball and also for allowing graphics and/or paint to adhere to the surface of the paddle.
  • the allowable limits for roughness set forth by the USAPA shall be no greater than 30 micrometers (pm) on the Rz reading (average maximum height, peak to valley), and no greater than 40 micrometers (pm) on the Rt reading (maximum height, peak to valley).
  • a lightly woven, textured peel ply or release film (usually with weight of 20-90 gsm, or even 25-55 gsm) is placed on the A-side (e.g., the exterior side) of the composite skin and cured with the skin.
  • the peel ply may then be removed, leaving behind a light texture that is slightly less than or equal to the IFP/USAPA regulations of 30 Rz and 40 Rt.
  • the surface would have a sharp high friction texture like a triangle wave and not a rolling texture like a sine wave.
  • the skins may be cured on this plate mold and when removed from the mold so that the texture would be imparted onto the exterior (“A”) surface of the skin.
  • A exterior
  • a heated textured roller may be used to impart texture to the skin surface after it has cured where the texture on the roller is similar to the flat plate surface proposed above and presses the specific surface texture into the mold.
  • the surface may have a sharp texture like a triangle wave and not a rolling texture like a sine wave. This shard texture allows for more friction between the ball and striking surface compared to a rounded sine wave like texture.
  • a perspective view of a paddle 100 (e.g., pickleball paddle, racket, etc.) is shown, according to an example embodiment.
  • the paddle 100 includes a sandwich panel 102 (e.g., paddle core), an edge guard 104, grip tape 106, and an endcap 108.
  • the sandwich panel 102 is formed in the shape of the paddle 100 and includes a striking portion 110, a handle portion 112, and a tapered portion 114 extending between and contiguous with both the striking portion 110 and the handle portion 112.
  • the sandwich panel 102 is formed in a non-paddle shape and is later cut out to have the shape shown in FIG. 1.
  • the sandwich panel 102 (FIG.
  • a core structure 118 is formed of a core structure 118 interposed between a first composite skin 120 and a second composite skin 122.
  • the composite skins 120, 122 are coupled with (e.g., coupled to, adhered to, cured with, etc.) the core structure 118, such as with an adhesive or resin through an autoclaving process.
  • the core structure 118 is cured with the composite skins 120, 122.
  • the composite skins 120, 122 are formed separately from the core structure 118 and are later coupled to the core structure 118, such as with an adhesive or resin.
  • the sandwich panel 102 provides an improved feel to the user of the paddle 100 without sacrificing rigidity and while still meeting the standards sets by the IFP.
  • the sandwich panel 102 also provides an improved aesthetic to the paddle 100 when compared to other paddles currently available for sale.
  • the natural aesthetic provided by flax, twill, hemp, and similar materials is often desirable by users of pickleball paddles.
  • the use of organic materials in a panel that meets the requirements of the IFP and the USAPA is unique to the industry.
  • the paddle 100 is defined by a central axis 125 extending along a longitudinal dimension of the paddle 100 and extending through the handle portion 112. In some embodiments, the paddle 100 is symmetrical about the central axis 125.
  • the paddle 100 further includes a first edge 128 (e.g., leading edge) that extends along a first end 130 of the sandwich panel 102. The first end 130 is positioned opposite to a second end 132 of the striking portion 110.
  • the first edge 128 is bisected (e.g., substantially bisected) by the central axis 125 and extends perpendicular to (e.g., substantially perpendicular to) the central axis 125.
  • the paddle 100 further includes a second edge 134 and a third edge 136, the third edge 136 being opposite to the second edge 134. Both of the second edge 134 and the third edge 136 extend parallel to the central axis 125 and extend perpendicularly to the first edge 128.
  • the first edge 128 is contiguous with both the second edge 134 and the third edge 136.
  • the first edge 128 and the second edge 134 meet at a first rounded corner 138.
  • the first edge 128 and the third edge 136 meet at a second rounded corner 140.
  • the first rounded corner 138 and the second rounded corner 140 are opposite to the handle portion 112.
  • the sandwich panel 102 is formed of a core structure 118 interposed between two composite skins, shown as a first composite skin 120 and a second composite skin 122.
  • first composite skin 120 and the second composite skin 122 are substantially similar (e.g., express similar material properties, such as stiffness and tensile strength).
  • first composite skin 120 and the second composite skin 122 are different and express different material properties.
  • the first composite skin 120 and the second composite skin 122 are coupled to the core structure 118 such that the core structure 118 is interposed between the first composite skin 120 and the second composite skin 122.
  • the first composite skin 120 is cured separately from the core structure 118 and is coupled with the core structure 118 after the first composite skin 120 is cured.
  • the first composite skin 120 is cured with the core structure 118 such that the first composite skin 120 and the core structure 118 are cured together.
  • a substrate 124 may be positioned between the composite skins 120, 122 and the core structure 118.
  • the substrate 124 is a non-woven fabric, such as a non-woven fabric formed from polypropylene, polyester, and similar polymeric materials.
  • the substrate 124 may be coupled (e.g., cured) directly to the core structure 118, such as by hot melt, an adhesive film, or a resin.
  • the core structure 118 may be formed of paper, synthetic paper, metal, composites, a polymeric material, or the like.
  • the core structure 118 includes a plurality of cells that extend through (e.g., perforate) the core structure 118.
  • the core structure 118 may be a honeycomb core.
  • the core structure 118 may include the substrate 124 that extends over the core structure 118prevent resin from seeping into the cells of the core structure 118.
  • the first composite skin 120 is a laminate structure and includes a plurality of fabric layers cured together with a resin.
  • the first composite skin 120 includes layers of fiber- reinforced resin (e.g., matrix resin in a cured and consolidated composite form).
  • the first composite skin 120 may include any number of fabric layers layered in various orientations relative to one another.
  • Each fabric layer is defined by a material (e.g., flax, hemp, Kevlar, carbon, wood, etc.), a directionality (e.g., biaxial, bidirectional, triaxial, uniaxial, unidirectional, etc.), a weave (e.g., twill, plain, satin, etc.), and a density (measured in grams per cubic centimeter (g/cm 3 ).
  • a directionality e.g., biaxial, bidirectional, triaxial, uniaxial, unidirectional, etc.
  • a weave e.g., twill, plain, satin, etc.
  • density measured in grams per cubic centimeter
  • the first composite skin 120 includes a first fabric layer 142 and a second fabric layer 144 coupled with (e.g., cured with) the first fabric layer 142.
  • the first fabric layer 142 may be a biaxial fabric.
  • the first fabric layer 142 includes a twill weave.
  • the first fabric layer 142 is formed of an organic material, such as flax or hemp.
  • the first fabric layer 142 is a plain weave hemp having a density of approximately 132 grams per square centimeter (g/cm 2 ).
  • the first fabric layer 142 includes a bidirectional weave having threads extending in a first x-direction 170 and having threads extending in a first y-direction 172.
  • the first fabric layer 142 includes a +45/-45-degree weave, where the first x-direction is perpendicular to (e.g., substantially perpendicular to) the first y-direction.
  • the first fabric layer 142 includes a 90/0-degree weave.
  • the first fabric layer 142 is a twill weave fabric. The twill weave may be a plain weave, a 2x2 weave, and the like.
  • the first fabric layer 142 is formed of an organic material, such as hemp, flax, wood, and the like.
  • organic material refers to materials related to or derived from living matter. Organic material does not include carbon fiber, fiberglass, aramid, and similar materials.
  • the first fabric layer 142 includes flax fibers in a twill weave pattern. In some embodiments, the first fabric layer 142 is formed from hemp fibers in a twill weave.
  • the first fabric layer 142 may have a density between 200-300 grams per square meter (gsm). In some embodiments, the first fabric layer 142 has a density of between 225-275 gsm. In some embodiments, the first fabric layer 142 has a density of between 240- 260gsm.
  • the second fabric layer 144 includes a bidirectional weave having threads extending in a second x-direction 174 and having threads extending in a second y-direction 176.
  • the second fabric layer 144 includes a 2x2 twill weave.
  • the second fabric layer 144 is formed of an organic material, such as flax or hemp.
  • the second fabric layer is a 2x2 twill weave flax fabric having a density of approximately 245 g/cm 2 .
  • the warp and weft threads (thread thicknesses, etc.) are of similar (e.g., the same but for manufacturing tolerances) thicknesses [0077] Referring now to FIG.
  • the first fabric layer 142 is positioned at an angle a relative to the second fabric layer 144.
  • the first x-direction 170 is aligned with at least one of the second x-direction 174 and the second y-direction 176.
  • the angle a is zero and the first fabric layer 142 is aligned with the second fabric layer 144 (FIG. 5).
  • the first fabric layer 142 is positioned within +/- 10 rotational degrees of being aligned with the second fabric layer 144.
  • the first x- direction 170 is positioned within 10 rotational degrees of at least one of the second x-direction 174 and the second y-direction 176.
  • the first fabric layer 142 is positioned at 45-rotational degrees relative to the second fabric layer 144 (FIG. 7).
  • the first x-direction 170 is positioned at approximately 45 rotational degrees of both the second x-direction 174 and the second y-direction 176.
  • the first fabric layer 142 is positioned at between 55-35 rotational degrees of the second fabric layer 144.
  • the first fabric layer 142 is interposed between the second composite skin 122 and the core structure 118 such that the second composite skin 122 is outwardly facing.
  • the second fabric layer 144 is positioned such that the second fabric layer 144 is aligned with the central axis 125, as shown in FIG. 2.
  • the second fabric layer 142 is positioned such that at least one of the second x- direction 174 and the second y-direction is substantially parallel to the central axis 125.
  • the second fabric layer 144 is positioned between -10-10 rotational degrees of the central axis 125 when the first composite skin 120 is coupled with the core structure 118. In some embodiments, the second fabric layer 144 is positioned at approximately 45-rotational degrees relative to the central axis 125.
  • the first fabric layer 142 and the second fabric layer 144 are “dry” fabrics that are impregnated with a resin (e.g., epoxy resin, polyester resin, vinyl ester resin, phenolic resin, bio resin, thermoplastic resins (polypropylene, PLA, polycarbonate), etc.).
  • a resin e.g., epoxy resin, polyester resin, vinyl ester resin, phenolic resin, bio resin, thermoplastic resins (polypropylene, PLA, polycarbonate), etc.
  • at least one of or both of the first fabric layer 142 and the second fabric layer 144 are prepreg sheets.
  • the term “prepreg” refers to fibers pre-impregnated with resin, such as a combination of a fibrous substrate (such as a mat, fiber, or cloth material) with resin impregnated on and into the substrate.
  • first adhesive film 180 Positioned between the first composite skin 120 and the substrate 124 may be a first adhesive film 180.
  • the first adhesive film 180 may be supported by a scrim.
  • second adhesive film 182 Interposed between the first fabric layer 142 and the second fabric layer 144 is a second adhesive film 182.
  • the second adhesive film 182 may include a scrim.
  • Positioned on the second fabric layer 144 opposite to the second adhesive film 182 is a third adhesive film 184.
  • the third adhesive film 184 is unsupported (e.g., does not include a scrim).
  • the third adhesive film 184 is outwardly facing when the sandwich panel 102 is cured.
  • a peel-ply 186 such as frosted glass or frosted aluminum, may be used to provide a texture 190 to a striking surface of the sandwich panel 102.
  • the texture 190 may be in compliance with the requirements of the IFP and the USAPA. Specifically, the average RT texture reading, taken in 6 directions, may be less than or equal to 40 microns and the average RZ texture reading, taken in 6 directions, is less than or equal to 30 microns.
  • a paddle 200 is shown, according to another example embodiment.
  • the paddle 200 is similar to the paddle 100. Accordingly, like numbering is used to denote like parts between the paddle 100 and the paddle 200.
  • a difference between the paddle 100 and the paddle 200 is that the paddle 200 includes a fabric layer having a unidirectional weave.
  • the paddle 200 includes the first composite skin 120 including a second fabric layer 244 that includes a unidirectional weave and is formed of flax fibers.
  • the second fabric layer 244 is aligned with the central axis 125.
  • the unidirectional fibers of the second fabric layer 244 may be flax fibers that provide a desirable wooden or natural look to the user of the paddle 200.
  • the second fabric layer 244 is pre-impregnated with a resin before assembling.
  • the second fabric layer 244 may be P-UD 3.2, supplied by LINGROVE®.
  • the second fabric layer 244 has a density of between 50-150gsm.
  • the second fabric layer 244 has a density of between 75-125gsm. In some embodiments, the second fabric layer 244 has a density of between 100-120gsm. [0083] Referring now to FIG. 9, a cut-away view of the paddle 200 is shown. The second fabric layer 244 is aligned with the first fabric layer 142.
  • FIG.10 depicts a layered helical laminate structure 302 including a plurality of layers 300a-30os. These layers can be stacked and impregnated with a resin to form a prepreg 304 as shown for example in FIG. 11.
  • FIG. 12 shows a first paddle design 306 using a core 308 formed of an additive manufacturing gyroid infill 310.
  • a second core type 312 is shown having a honeycomb configuration 314.
  • a third core configuration 316 is shown including a honeycomb inner core 318 and a gyroid outer core 320.
  • the core may be formed to have specific shapes found in nature (“biomimicry”). As one example, FIGS. 13A-13D shows a core 322 formed in a spiral 324 having a resulting spider web type shape 326. It is possible that in this or other configurations, portions of the material for forming the core may be thicker than others. In this specific spiral example, the inner portion of the spiral 328 may have a thinner cross section at its widest point then the portion of the spiral 330 located along the outermost section of the paddle. In one embodiment, the thickness of the material increases in a progressive manner as the material moves from the inner portion of the spiral 328 to the outer portion of the spiral 330. The increase may be at least about 20%, at least about 30%, at least about 40%, or even at least about 50% when comparing the inner portion 328 to the outer portion 330.
  • FIGS. 14A-14D shows variations on exemplary paddle cores having a “tree-like” format.
  • Each core includes one or more primary branch portion 332. Extending from each primary branch portion 332 are one or more secondary branch portions 334.
  • tertiary branch portions 336 are shown extending from the secondary branch portions 334. At each point where a secondary branch portion 334 or tertiary branch portion 336 extends from a primary branch portion 332 or secondary branch portion 334 respectively, the branch portions may split in accordance with a unique ratio. This ratio may be in accordance with Murray's law.
  • the use of such ratios may be optimal for providing light weight support and channeling energy and vibrations to the paddle handle/user for optimal responsiveness, feel, and/or performance. It is also possible that vibrations may be reduced along the branches.
  • the paddle core may include a sandwich panel arrangement. Specific exemplary sandwich panel arrangements are shown in FIG. 15 and FIG. 16. FIG.
  • FIG. 15 depicts sandwich panel structures 338, 342 that mimic a “bone-like” arrangement having meandering wall structures that curve to form cavities 340, 344 of varying sizes and shapes.
  • FIG. 16 shows various sandwich panel constructions 346, each including a core portion 348 that includes a plurality of cavities 350 along a length of the core portion 348.
  • FIG. 17 shows a recycled cardboard grid arrangement for the core 352.
  • the grid appears in a stacked format, where a first grid of cardboard having a plurality of first parallel ribs 354 is stacked onto a second grid of cardboard having a plurality of second parallel ribs 356 that are arranged perpendicular to the first parallel ribs 354.
  • the cardboard being a porous material
  • the cardboard can be impregnated with a resin 358) that is adapted to adhere the grid portion to one or more facing sheets (not shown).
  • the material for forming a paddle core may include woven and nonwoven composite structures. These structures may be formed of materials that are specifically adapted for being coated and/or impregnated with a resin material, which may be a thermoplastic or thermoset resin and may have adhesive and/or foaming characteristics.
  • FIG. 18 shows an exemplary woven core material 360 including a plurality of identical hexagonal cavities 362 formed by a plurality of wall structures 364.
  • the wall structures 364 may include material 366 that is porous and able to absorb a resin.
  • FIG. 19 shows similar woven materials 368 for forming a paddle core. Each sample 368 has a different thickness than the others and each includes top and bottom walls 372 and cavities 370 formed in between the top and bottom walls 372.
  • FIG. 20 shows a recycling flow chart for use of recycled paddle core materials.
  • the paddle 374 is adapted for being ground into pellets 376.
  • the pellets could be treated to have a desired appearance (dyed, bleached, coated, sprayed or the like).
  • the pellets could be molded into balls 378 (which may be pickleball balls). The resulting balls could later be further recycled by being ground into pellets 380 and combined with the paddle pellets 376 to form more balls 378.
  • the terms “approximately,” “about,” “substantially,” and similar terms generally mean +/- 10% of the disclosed values, unless specified otherwise.
  • the terms “approximately,” “about,” “substantially,” and similar terms are meant to cover minor variations in structure that may result from, for example, the manufacturing or assembly process and are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the disclosure as recited in the appended claims.
  • Coupled means the joining of two members directly or indirectly to one another. Such joining may be stationary (e.g., permanent or fixed) or moveable (e.g., removable or releasable). Such joining may be achieved with the two members coupled directly to each other, with the two members coupled to each other using a separate intervening member and any additional intermediate members coupled with one another, or with the two members coupled to each other using an intervening member that is integrally formed as a single unitary body with one of the two members.
  • Coupled or variations thereof are modified by an additional term (e.g., directly coupled)
  • the generic definition of “coupled” provided above is modified by the plain language meaning of the additional term (e.g., “directly coupled” means the joining of two members without any separate intervening member), resulting in a narrower definition than the generic definition of “coupled” provided above.
  • Such coupling may be mechanical, electrical, or fluidic.
  • any member of a genus may be excluded from the genus; and/or any member of a Markush grouping may be excluded from the grouping.
  • any numerical values recited herein include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value.
  • the amount of a component, a property, or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70
  • intermediate range values such as (for example, 15 to 85, 22 to 68, 43 to 51 , 30 to 32 etc.) are within the teachings of this specification.
  • individual intermediate values are also within the present teachings.

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  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne une raquette comprenant une partie de frappe définissant un axe central, une partie poignée et une partie conique contiguë à la fois à la partie poignée et à la partie de frappe ; une structure sandwich comprenant une couche centrale et un premier revêtement accouplé à la couche centrale, le premier revêtement comprenant une première couche de tissu et une seconde couche de tissu accouplée à la première couche de tissu.
PCT/US2022/024013 2021-04-09 2022-04-08 Raquettes composites et procédés de formation associés WO2022217045A1 (fr)

Priority Applications (3)

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US18/286,139 US20240189679A1 (en) 2021-04-09 2022-04-08 Composite Paddles and Methods for Forming same
EP22719467.7A EP4319893A1 (fr) 2021-04-09 2022-04-08 Raquettes composites et procédés de formation associés
CN202280041415.6A CN117460562A (zh) 2021-04-09 2022-04-08 复合材料拍子及其形成方法

Applications Claiming Priority (2)

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US202163172752P 2021-04-09 2021-04-09
US63/172,752 2021-04-09

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Publication number Priority date Publication date Assignee Title
EP4173679A1 (fr) * 2021-10-28 2023-05-03 Sumitomo Rubber Industries, Ltd. Batte de padel
TWI824826B (zh) * 2022-11-17 2023-12-01 美商吉爾伯斯股份有限公司 具有變化紋路的表面層之匹克球拍結構及其製造方法

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US20160193793A1 (en) * 2015-01-06 2016-07-07 Gear Box Panel Structure with Foam Core and Methods of Manufacturing Articles Using the Panel Structure
US20170136325A1 (en) * 2015-11-12 2017-05-18 Down Under Tennis, Inc. Sound absorbing game paddle
US20180104555A1 (en) * 2016-10-19 2018-04-19 Charles E. Taylor Pickleball paddle and method
JP2019522119A (ja) * 2016-07-05 2019-08-08 サン−ゴバン アドフォル 複合材を補強するためのハイブリッド布地

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Publication number Priority date Publication date Assignee Title
US20160193793A1 (en) * 2015-01-06 2016-07-07 Gear Box Panel Structure with Foam Core and Methods of Manufacturing Articles Using the Panel Structure
US20170136325A1 (en) * 2015-11-12 2017-05-18 Down Under Tennis, Inc. Sound absorbing game paddle
JP2019522119A (ja) * 2016-07-05 2019-08-08 サン−ゴバン アドフォル 複合材を補強するためのハイブリッド布地
US20180104555A1 (en) * 2016-10-19 2018-04-19 Charles E. Taylor Pickleball paddle and method

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP4173679A1 (fr) * 2021-10-28 2023-05-03 Sumitomo Rubber Industries, Ltd. Batte de padel
TWI824826B (zh) * 2022-11-17 2023-12-01 美商吉爾伯斯股份有限公司 具有變化紋路的表面層之匹克球拍結構及其製造方法

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CN117460562A (zh) 2024-01-26
EP4319893A1 (fr) 2024-02-14

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