Pickleball Ball With Reinforced Holes And/Or Patterned Surface

CROSS REFRENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority from U.S. Provisional Application No. 63/718,912 filed on November 11, 2024, the entire content of which is herein incorporated by reference.

FIELD

[0002] This disclosure relates generally to pickleball, and more particularly to pickleball balls.

BACKGROUND

[0003] A pickleball ball is constructed with a light weight plastic and has holes in a pattern that extend throughout the surface of the hollow shell of the ball. The material and the hole patterns are instrumental in the pickleball ball’s overall light weight and therefore its aerodynamics, noise generation during play, and appeal to a wide variety of players.

[0004] However, conventional pickleball balls are prone to develop cracks relative quickly and/or generate too much noise. These and some other aspects of existing pickleball balls, have led to the desire for improved pickleball balls.

SUMMARY OF EXAMPLE EMBODIMENTS

[0005] In an embodiment, a pickleball ball comprising a spherical hollow shell and holes distributed on the shell is provided wherein the holes are reinforced around edges of the holes and/or on inner walls of the holes. Each hole of the holes is reinforced around an edge of the hole and/or on an inner wall of the hole by a layer of durable material around the hole. The layer of durable material may be made of a different material than a material of the hollow shell, may be made of a different density than a material of the hollow shell, may be made of a different thickness than a material of the hollow shell, or is a different layer on a material of the hollow shell.

[0006] The holes may be reinforced around edges of the holes by the layer of durable material, may be reinforced on inner walls of the holes by the durable material, and/or the layer of durable material may comprise a ring structure attached to the perimeter of each hole on the inside of the hollow shell. In some examples, a ring structure may be molded on to the perimeter of each hole, may be glued on to the perimeter of each hole, may be constructed from a flexible material, may form a seamless integration with the inner surface of the hollow shell, or may comprise ribs and/or protrusions.

[0007] In some examples, an inner wall of each of the hole may be lined with a layer of durable material. The layer of durable material may comprise a high-strength plastic, polymer or a composite material, and/or may extend beyond each hole’s edge to create a smooth transition and reduce peeling.

[0008] In some examples, the hollow shell may be formed using reinforced plastic composite material comprising distributed reinforcing fibers, wherein the distribution of reinforcing fibers along the perimeter of each of the holes comprises a higher concentration of the reinforcing fibers than in areas away from the perimeter. The fibers may be glass or carbon fibers. The reinforced plastic may comprise the distributed fibers sandwiched between two polymer layers. The reinforcing fibers may comprise short reinforcing fibers having a length between 0.1 mm and 0.5 mm arranged in direction perpendicular to the surface of the pickleball ball. The short reinforcing fibers may be selected from the group consisting of glass fibers and carbon fibers. The concentration of the short reinforcing fibers may be between 10% and 20% by weight in areas surrounding the holes, and between 5% and 10% by weight in other areas of the shell. In some example, when the reinforcing fibers are short reinforcing fibers, additives selected from the group consisting of coupling agents, UV stabilizers, and antioxidants may be included.

[0009] In some examples, the hollow shell may be formed using plastic compound that varies hardness to surround the perimeter of each hole by a harder plastic relative to that away from each hole. The harder plastic may be formed by post-molding selective hardening, or may be formed by dual-injection molding.

[0010] In some examples, each of the holes may be reinforced by a ring structure attached to the perimeter of each hole on the outside of the hollow shell. The ring structure may be molded on to the perimeter of each hole, may be glued on to the perimeter of the each hole, may be constructed from a flexible material, or may comprise a durable impact-resistant material and is bonded securely to the surface. The impact-resistant material may be aerodynamically neutral. The ring structure may form a seamless integration with the outer surface of the hollow shell.

[0011] In some examples, the outer surface of the hollow shell comprises a deterministic pattern of micro artifacts. The micro artifacts may be micro notches, micro bumps, and/or micro indentations. In some examples, the deterministic pattern on the outer surface is comprised in an overlay layer, and/or is a layer of grit.

[0012] In some examples, the surface of the hollow shell of the pickleball ball comprises a deterministic pattern of indentations.

[0013] In an embodiment, a pickleball ball comprising a spherical hollow shell and holes distributed on the shell is provided wherein the surface of the hollow shell comprises a deterministic pattern of grit and/or indentations.

[0014] In an embodiment, a pickleball ball comprising a spherical hollow shell, and holes distributed on the shell is provided where the hollow shell is formed by using a plastic compound that varies hardness to surround the perimeter of each of the holes by a harder plastic relative to that away from the each hole, and/or a reinforced plastic composite material comprising distributed reinforcing fibers. The distribution of reinforcing fibers along the perimeter of each of the holes comprises a higher concentration of the reinforcing fibers than in areas away from the perimeter.

[0015] In an embodiment, a method of manufacturing a reinforced pickleball is provided. The method comprises preparing a composite material by compounding high-density polyethylene (HDPE) with short reinforcing fibers in a twin-screw extruder, and injection molding the composite material into a spherical body with a plurality of holes using a mold with strategically placed gates to direct fiber flow around hole areas, wherein the injection molding process utilizes a sequential valve gate system to optimize fiber orientation around the holes.

[0016] In an example, the method may include utilizing a multi-shot injection process, wherein a first shot injects a core material with a lower fiber content, and a second shot injects a higher fiber content material around hole areas. In an example, the method may include subjecting the molded pickleball to a post-molding annealing process to relieve internal stresses.

[0017] In an embodiment, a pickleball mold for creating reinforced pickleball balls is provided. The mold comprises a spherical cavity for forming a body of the pickleball ball, a plurality of protrusions within the cavity for forming holes in the pickleball ball, a hot runner system with a sequential valve gate system, and gates located to direct the flow of fiber-reinforced plastic material around the holes during the injection molding process.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Some features are shown by way of example, and not by limitation, in the accompanying drawings. In the drawings, like numerals may reference similar elements.

[0019]FIG. 1A shows an example pickleball court, in which embodiments of the present disclosure may be applied.

[0020]FIG. 1B shows another view of a pickleball court.

[0021]FIG. 2 shows a conventional pickleball ball.

[0022]FIG. 3 shows a conventional pickleball ball in which the shell has been damaged by use.

[0023]FIG. 4 illustrates a pickleball ball with reinforced holes where the holes are reinforced on the inside of the hollow shell of the ball, according to some embodiments of the present disclosure.

[0024]FIGS. 5A-5B illustrate a pickleball ball with reinforced holes where the inner walls of the holes are reinforced, according to some embodiments of the present disclosure.

[0025]FIGS. 6A-6B illustrate a reinforced plastic that is used to construct a pickleball ball with reinforced holes, according to some embodiments of the present disclosure.

[0026]FIG. 7 illustrates a pickleball ball with the holes reinforced by harder plastic surrounding the holes, according to some embodiments of the present disclosure.

[0027]FIG. 8 illustrates a pickleball ball with reinforced holes where the holes are reinforced on the outside of the hollow shell of the ball, according to some embodiments of the present disclosure.

[0028]FIG. 9 illustrates a irregular texture pattern on an example conventional pickleball ball.

[0029]FIG. 10 illustrates some example regular patterns of texture artifacts on the outer surface of the hollow shell of some pickleball balls, according to some embodiments of the present disclosure.

[0030]FIG. 11 illustrates a pickleball ball with the surface area between holes having a regular pattern of circular indentations, according to some embodiments of the present disclosure.

[0031]FIG. 12 illustrates a pickleball ball with the surface area between holes having a regular pattern of grit, according to some embodiments of the present disclosure.

[0032]FIG. 13 illustrates a pickleball ball with the surface area between holes having a regular pattern of micro indentations, according to some embodiments of the present disclosure.

[0033]FIG. 14 illustrates a pickleball ball that comprises reinforced holes and a deterministic patterned surface, according to some embodiments of the present disclosure.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0034] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the disclosure. However, it will be apparent to those skilled in the art that the disclosure, including structures, systems, and methods, may be practiced without these specific details. The description and representation herein are the common means used by those experienced or skilled in the art to most effectively convey the substance of their work to others skilled in the art. In other instances, well-known methods, procedures, components, and circuitry have not been described in detail to avoid unnecessarily obscuring aspects of the disclosure.

[0035] References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0036] This disclosure relates to “Pickleball,” a game that has in recent years seen a massive increase in popularity among all age groups of players, including among senior citizens. Pickleball is a game that can be described as combining aspects of tennis, badminton, and ping-pong. It is played on a badminton-sized court, with paddles and a ball similar to a wiffle ball, but slightly smaller in size. The net used in pickleball is similar to a tennis net in some ways, but is lowered at the center.

[0037] Pickleball has recently become very popular and is played both indoors and outdoors, as either doubles or singles. The rules are relatively simple and the game is easy for beginners to learn. However, among skilled players, pickleball can develop into a quick, fast-paced, and competitive game.

[0038]FIG. 1A shows an example pickleball court 100 that includes a pickleball playing surface 130 and a pickleball net 132. The playing surface 130 comprises two left serve areas 102 and 108, two right serve areas 104 and 106, and two non-volley areas 110 and 112, with one of the left serve areas, one of the right serve areas, and one of the non-volley areas being on each side of the pickleball net 132. The net is 36 inches tall at the edges, and lowered to 34 inches in the middle. The areas 102-112 are defined by baselines 118 and 120 each 20 feet, sidelines 114 and 116 each 44 feet, center lines 122 and 124 each 15 feet, and non-volley lines 126 and 128 each the same size as a baseline. Each of the lines may be 2 inches wide. The term “court line” is used in this disclosure to refer to any sideline, baseline, centerline or non-volley line on the pickleball court. Non-volley areas 110 and 112, each extending 7 feet from the net, are also referred to as the “kitchen”.

[0039]The game of pickleball is played with a pickleball paddle 134 and pickleball ball 136. The ball 136 is typically made of plastic and has a 3-inch diameter. Similar to a wiffleball, the ball 136 has through holes throughout the surface. Different types (e.g., with different levels of hardness and different sizes of the through holes) may be used for playing the game on the various types of pickleball courts (e.g., indoor, outdoor, hard surface, soft surface etc.).

[0040] Pickleball can be played as singles or doubles, and is most commonly played as doubles. Each point begins with an underarm serve. The serve is performed diagonally beginning at the right-hand service square. A valid serve sends the ball from one left serve area to the other left serve area or from one right serve area to the other right serve area. The serve must clear the non-volley-zone. The serve must bounce before being hit by the receiver. The return of serve must also bounce before being hit (this is known as the 2 bounce rule). After the serve and the return of the serve, the ball can land anywhere on the opposite side of the playing surface 130. Volleys can only be performed outside of the non-volley zone. Volleys, that is, hitting the ball in the air without first letting it bounce, can only be made after the 2 bounce rule has been followed. However, if the ball is hit from within the kitchen, then it cannot land in the kitchen on the other side of the net.

[0041] A fault is any action that stops play due to a rule violation. A fault by the receiving team results in the servers earning a point. A fault by the serving team results in the server’s loss of service and/ or side out. A fault is committed when the serve touches any part of the non-volley zone (including the line) or the ball is hit out of bounds.

[0042]Pickleball games are typically played without a referee and are self-judged. Each player makes the line calls as to whether the ball is in or out when the ball contacts the playing surface on that player’s side. The game continues to at least 11 points and requires a 2-point difference for a win. FIG. 1B shows another view of a pickleball court.

[0043] As noted above, pickleball is played by people of all ages and all skill levels. It is important that pickleball organizations provide as many options as possible to facilitate enjoyable play among players with different skill levels, practice needs, athletic capabilities, etc. The pickleball ball can be constructed in manners that provide for facilitating such options for players.

[0044] An example pickleball ball 200 is shown in FIG. 2. Specifications for pickleball balls are established by United States Pickleball Association (USPA). The specification defines requirements for construction, approval, size, bounce, compression, and design of pickleball balls. These specifications are intended for maintaining consistent playing characteristics across all pickleballs. Most pickleball balls approved for competition use are compliant with the USPA specifications.

[0045]USPA construction specifications require that the ball is made of a durable material molded with a smooth surface and free of texturing. The ball may have a slight ridge at the seam, as long as it does not significantly impact the ball’s flight characteristics. Size specifications require that the ball shall be 2.87 inches (7.29 cm) to 2.97 inches (7.54 cm) in diameter. The maximum out-of-round diameter variance shall not be greater than +/-0.020 inch (0.51 mm). This provides a circumference 202 between 9.03 inches (22.93 cm) and 9.34 inches (23.72 cm). Weight specifications require that the ball weighs between 0.78 and 0.935 ounces (22.1 and 26.5 grams).

[0046] The specifications also require certain bounce characteristics and compression characteristics for the ball. Further, the specifications require that the ball shall have a minimum of 26 to a maximum of 40 circular holes (e.g., holes 204), with spacing of the holes and overall design of the ball conforming to flight characteristics.

[0047] One technique of manufacturing pickleball balls is a process referred to as injection molding. The core ingredient is very often polyethylene - a type of plastic known for its toughness and elasticity. However, the type of plastic can differ depending on whether the ball is for indoor or outdoor play. Indoor balls use softer plastic (e.g., polypropylene) for better control on smooth surfaces, while outdoor balls have shells made of harder plastic to endure the wear and tear of rough courts like asphalt or concrete.

[0048] The injection molding process involves melting down the plastic into a liquid state and then forcing the liquid plastic with high pressure into a mold made of two halves. These molds are designed to create the exact shape and size of a pickleball, including the holes on the surface. The pressure ensures the plastic fills the mold in a manner that results in a consistent ball construction throughout. The two halves of the filled mold are then fused together forming a complete ball. Thereafter, the new ball cools down until the plastic hardens and retains its shape.

[0049] Rotational molding is another process that is used for manufacturing pickleballs. In this technique, plastic powder is poured into a heated mold that rotates on two axes. As the mold rotates, the plastic melts and coats the inside evenly. The mold is then cooled, and the finished ball is removed. In general, rotational molding is considered a less-costly process than injection molding, but it offers less flexibility in the ball design. Thus, injection molding is generally preferred.

[0050] Pickleballs balls that are available in the market are made of one plastic type. The material composition may be tailored to particular playing surfaces. As mentioned above, for indoor pickleball, balls are made with a softer plastic, like polypropylene, for better control on smooth gym floors. The softer plastic materials are considered to provide more precise volleys and softer touches. For outdoor pickleball, balls that have tougher shells of harder plastic, like polyethylene, to withstand the demands of asphalt or concrete courts are used. Such tougher shells are more resilient to wear and tear and have a faster, livelier bounce for outdoor rallies.

[0051]The characteristic of the plastic type is a key factor that determines the durability, bounce, hardness and weight of the ball. Typically, a pickleball ball is considered to last for 3-5 games at maximum performance before it is typically recommended to be switched out.

[0052] Currently available pickleball balls are constructed from one material such as polyethylene or polypropylene, and has holes spaced evenly throughout the surface. Balls with different numbers of holes are available. While most available pickleball balls have circular holes, balls that have holes that are shaped as stretched circles (e.g., stretched from top and bottom of circle) are also available. The holes may function to change the drag imposed on the ball when in flight, and to reduce the weight of the ball. The even distribution of the holes may be instrumental in providing for consistent rotation and spin behavior of the ball. Consistent rotation and spin behavior can improve predictability of the ball’s path to a player.

[0053] The conventional pickleball balls such as that shown in FIG. 2 may frequently develop cracks in the plastic shell. Often the cracks originate at the edge of one of the holes on the surface of the pickleball ball. As noted above, the holes arranged in a regular pattern and distributed throughout the surface of the hollow shell of the pickleball ball reduce weight of the ball, alter the structural properties of the shell, allows airflow through the ball, and may affect the acoustic properties (e.g., noise generated upon impact with paddle or court surface) of the ball. The holes also may also reduce structural strength of the shell, and impact stress distribution within the shell, and may concentrate the stresses around the holes.

[0054] Pickleball is played on a hard surface, and thus a pickleball ball can quickly break. Pickleball balls typically break (crack) starting from holes. Typically, broken areas are connected to a hole. Sometimes, broken areas are between the holes.

[0055]FIG. 3 illustrates a conventional pickleball with example cracks in the hollow shell that have occurred in relation to the pre-made holes of the ball. The crack 310 is shown to extend in the surface of the shell 308 between holes 302 and 304. Smaller cracks such as crack 312 are shown to extend out from each of the holes 302 and 304. Crack 312 may have originated at the outer edge of hole 302 and may have gradually, with use of the ball for play, spread to the outer edge of hole 304. The crack 310 may be through the entire width of the hollow shell, or may be only on one of either the outer or inner surface. The extent of the crack, that is, the length of the crack and/or the depth of the crack, affects the structural strength of the ball and also the behavior of the ball. Crack 312, which is substantially less extensive than crack 310, may have occurred recently, and the ball may not have been used in play thereafter. Cracks 310 and 312 may also have a portion that extends on the inner wall of the respective holes. For example, crack 312 may extend over the entire height (depth) of the inner wall 306 of the hole 304.

[0056] There is a need to extend the lifespan of a pickleball ball. Some manufacturers create pickleball balls with smaller holes in order to reduce cracking. However, smaller holes can make the pickleball ball hard, stiff and capable of causing injuries to players on impact.

[0057] Example embodiments extend the lifespan of a pickleball without substantially impacting the experience with the ball in a pickleball game. Some embodiments of the present disclosure provide a solution to the problem of cracks occurring in relation to pre-made holes on the shell of the pickleball ball. Some embodiments provide pickleball balls with reinforced holes so that the edge of each hole is strengthened.

[0058] Hole edge reinforced pickleball balls (referred to herein sometimes as “reinforced pickleball ball”) according to example embodiments provide increased durability and lifespan by reducing the likelihood of cracks or other deformations at the most common locations for such occurrences – the holes on the hollow shell. The hole edge reinforcements of example embodiments may be configured to maintain the behavior of a new ball consistently over time and/or to improve certain play characteristics. For example, some embodiments provide for customization of ball behavior properties (e.g., flight characteristics) through selective reinforcement of hole edges. The availability of longer lasting pickleball balls would also reduce waste and environmental impact due to pickleball balls.

[0059] Another problem with some conventional pickleball balls is that the ball surface can be such that the ball behavior can change depending on what part of the ball’s surface strikes the pickleball court surface and/or the paddle, and thus results in unpredictable behavior. Such unpredictable ball behavior may reduce the enjoyability of the game.

[0060] Different pickleball balls manufactured by different manufacturers for indoor and outdoor play have different levels of roughness on the surface of the pickleball ball. The different levels of roughness create a level of friction and grit when the ball hits the paddle or the surface of the court.

[0061] The smoothness of the surface of currently available pickleball balls is randomly uniform. No pickleball ball that is currently available, have organized and deterministic texture patterns on the surface, and most ball customizations are limited to the hole pattern. In many currently available pickleballs, the ball surface does not have sufficient grit. Inadequate grit on the surface causes pickleball balls to bounce from the ground (e.g., court surface) in a manner that is inconsistent, as there is not enough friction between the ball and the ground. It is also difficult to get consistent strokes with spin when the pickleball ball is hit with a pickleball paddle because ball surface does not have sufficient grit when it hits the paddle.

[0062] An example, texture pattern of the outer surface of an example conventional pickleball ball is shown in FIG. 9. The irregular distribution of artifacts over the surface of the hollow shell of a pickleball results in the ball behavior changing from one surface impact to another based, among other things, also on the texture pattern at the point of impact. Some embodiments of the present disclosure provide a solution to the problem of unpredictable ball behavior caused by ball surface texture. More particularly, some embodiments have a regular pattern of artifacts distributed over the entire surface of the hollow shell.

[0063]FIG. 4 illustrates a reinforced pickleball ball 400 that comprises reinforced holes where the holes are reinforced on the inside of the hollow shell of the ball, according to some embodiments of the present disclosure.

[0064] The holes (e.g., 404) of the ball 400 are reinforced by a ring structure 402 at the internal edges (perimeter) of the holes. For example, the dashed-line circle 406 illustrates the positioning of the ring structure 402 at the hole 404 on the inside surface of the hollow shell of the ball 400. The ring structure 402 may be similar to an O-ring and may be made of a flexible, durable material such as, for example, silicone or a soft thermoplastic elastomer. The ring structure 402 is attached (e.g. molded, attached, or glued) directly into the ball during the manufacturing process, creating a seamless integration with the ball's structure. The ring structure reinforces each hole from the inside of the hollow shell of the ball, and therefore the outside of the ball may not require to be modified to accommodate the ring structure. The reinforcing of the perimeter of the hole reduces the likelihood of damage occurring around the holes. This may increase a lifespan of the pickleball.

[0065] The manufacturing process for a reinforced pickleball ball according to this embodiment may be more difficult to implement compared with using an exterior ring structure. An example manufacturing process may include the steps of designing a mold for the ball, creating a three dimensional model of the ball, molding each half of the ball separately, and combining the two halves of the ball, as with conventional pickleball balls but may additionally include adding the hole edge reinforcements before the two halves of the ball are fused together. Moreover, the mold and/or the injection mechanism may be configured to enable the addition of hole edge reinforcements.

[0066] The first step of designing the mold can be done using computer-aided design (CAD) software. The mold should be designed with reinforced holes on the spherical surface. This can be done by adding a thicker section of material around the holes to a predetermined height and width from the inner surface of the ball or by adding a separate piece of material of a predetermined height and width around the edge of each hole from the inside surface of the ball to the mold that will form the edge of each opening. The thicker section of material or the separate piece of material provides reinforcement to the hole edges and can have a height that can extend up to slightly below the outer surface of the ball’s shell so that the outer surface is not affected by the reinforcement. In an example, the ball may be made of a different material around the holes to provide reinforcement to the hole edges. One or more materials may be added to the ball around the holes to reinforce the ball around the holes. In an example, this may be implemented without substantially impacting the thickness of the ball around the holes.

[0067] The 3D model of the mold can be made using a mold machined from a block of metal (or, for example, by 3D printing). The mold can then be used to mold each half of the ball. This may be done using injection molding to inject molten plastic into the mold cavity. The plastic is allowed to cool and harden, forming the shape of each half of the ball. The reinforcement can be added to the mold at this point. This can be done by adding a thicker section of material around the opening or by adding a separate piece of material to the mold that will form the openings. Once each half has cooled and hardened, they can be removed from the mold and combined (e.g., fused together) to form the ball. The two halves are carefully aligned to ensure the holes match up, and the halves are then joined together. The joining may be performed using sonic welding, heat welding, or adhesive bonding. Sonic welding includes high-frequency sound waves being used to vibrate and melt the plastic at the seam, fusing the halves together. Heat welding includes the seam being heated, causing the plastic to melt and fuse. Adhesive bonding applies a strong adhesive to the seam to bond the halves together.

[0068] If the holes were not formed during injection molding, a drilling machine is used to create the precise pattern of holes on the pickleball.

[0069] Finishing of the ball may include trimming off any excess plastic or flash from the molding process, and smoothing and polishing the ball to remove rough edges or imperfections. Subsequently, the pickleball may be inspected for any defects in shape, size, hole pattern, or surface finish. The pickleball may be then labeled with the manufacturer's logo, model name, and other relevant information.

[0070] In some embodiments, the primary material of the pickleball ball is a high-density polyethylene (HDPE) resin or a similar thermoplastic. This is usually supplied in pellet form. Color pigments may be added to the resin pellets to achieve the desired color for the pickleball. As noted above, injection molding can be used to form the pickleball ball. The resin pellets and colorant are fed into an injection molding machine, where they are heated and melted into a viscous liquid. The molten plastic is injected under high pressure into a mold cavity shaped like two halves of a pickleball.

[0071]FIG. 5A illustrates a pickleball ball 500 with reinforced holes where the inner walls of the holes are reinforced, according to some embodiments of the present disclosure.

[0072] This approach involves lining the perimeter of the holes with a thin layer of a more durable material. The lining material may be made, for example, from a high-strength plastic, polymer or a composite material and provides the reinforcing ring structure to the hole. The lining is applied to the interior surface of each hole that is to be reinforced. The lining may optionally extend slightly beyond the hole’s edge to create a smooth transition to the outer surface, and optionally the inner surface, of the ball and prevent peeling.

[0073] The lining around the perimeter of the hole reduces the likelihood of the occurrence of cracks and other deformities around the holes. This may increase a lifespan of the pickleball and promote consistent behavior of the ball over time.

[0074] The illustrated ball 500 has at least some of its holes with their inner walls lined with the reinforcing material. Hole 504 is illustrated in more detail in the breakout 502 in FIG. 5B. The inner wall of the hole 504 is lined with the ring structure 506 of reinforcing material illustrated in dark shading. In some embodiments, parts 508 of the ring structure 506 extends slightly over the edge on the inner and/or outer surfaces of the ball. The extensions 508 may be small and low profile such that they do not extend significantly beyond the perimeter of the hole and do not significantly affect the evenness of the ball’s outer surface. In the illustrated embodiment, the extensions 508 are staggered around the perimeter, but some embodiments may have the extension extend continuously throughout the circular perimeter.

[0075] In some embodiments, the ring structure 506 is made of a higher strength plastic than the rest of the hollow shell of the ball. In some embodiments, ring structure 506 is a resin, or resin coating.

[0076] In some other embodiments, the ring structure reinforcing the inner walls of holes may be ribbed or comprise protrusions. Ribs or protrusions on the inner wall of a hole can increase the structural strength of the inner wall by increasing the cross-sectional area of the wall and provides for the stress on the inner walls (or the perimeter) of the hole to be more widely distributed. The protrusions can extend towards the center of the hole. The ring structures around respective holes, as shown in FIG. 5A, may extend to varying distances from the perimeter of the respective holes but are separated such that they do not contact each other.

[0077] A manufacturing process including a creation of a three dimensional mold and an injection molding process in a manner similar to that described in relation to FIG. 4 may be used to manufacture pickleball balls according to the embodiments shown in FIG. 5A-5B. In some embodiments, the reinforcing material of the ring structures can be injected in a second injection step after the molten plastic from the first injection has partially cooled in the mold to form the inner walls of the holes. The reinforcing material, for example, a harder plastic, for the inner surface of the inner wall of a hole may be injected by the second injection so that it fully adheres to the partially hardened wall of the hole and subsequently cools to form an integrated inner wall and reinforcing ring. When the reinforcing ring structure is formed with a resin or other coating, in some embodiments, such resin or other coasting may be sprayed (or applied) on the inner wall of a hole during the manufacturing process before the two halves of the ball are combined. In some embodiments, the resin or other coating may be applied on the inner wall of a hole after the complete ball has been fully formed.

[0078]FIG. 6A illustrates a reinforced plastic structure that is used to construct a pickleball ball with reinforced holes, according to some embodiments of the present disclosure. In some embodiments, the reinforced plastic structure method involves incorporating short fibers into the plastic matrix of the pickleball to enhance its overall strength and crack resistance. This method focuses on creating a composite material that maintains the ball’s required weight and performance characteristics while significantly improving its durability.

[0079] In an example, the entire ball may be manufactured using the reinforced plastic compound. This could involve adding short fibers (such as glass or carbon fibers) to the plastic matrix, increasing the overall strength and crack resistance of the material. The fiber content and distribution around the hole areas may be optimized to further strengthen the holes. FIG. 6A illustrates a cross-section of a reinforced plastic 602. The plastic 602 comprises a stack of microfibers 608 sandwiched between two layers 604. A layer of adhesive 606 enables the microfibers 608 to be held tightly between the two outer plastic layers 604. The outer plastic layer 604 may be a polymer (resin) sheet.

[0080]FIG. 6B illustrates an example arrangement of the microfiber layer 608 adjacent to the perimeter of a hole 610 of an example pickleball ball. An area 612 immediately adjacent to the perimeter of the hole is constructed with a higher density of microfibers in the microfiber layer 608 than the area 614 further out from the perimeter of the hole 610.

[0081]The microfiber may be made of glass fibers or carbon fibers. An example glass fiber used in some embodiments may include E-glass fibers of length 0.2 - 0.5 mm, diameter: 10 - 20 micrometers, and concentration: 10-15% by weight. An example carbon fiber used in some embodiments may include PAN-based carbon fibers of length 0.1 - 0.3 mm, diameter:5 - 10 micrometers, and concentration: 5-10% by weight.

[0082]The plastic matrix may be constructed using HDPE as the primary material. HDPE may be chosen for its balance of strength, flexibility, and ease of processing. Additives may include one or more coupling agents (e.g., maleic anhydride grafted polyethylene) of 0.5-1% to improve fiber-matrix adhesion, one or more UV stabilizers of 0.1-0.3% to prevent degradation from sunlight exposure, and one or more antioxidants of 0.1-0.2% to prevent oxidation during processing and use.

[0083] The manufacturing process may include a material preparation stage, a compounding stage, an injection molding stage, a post-molding treatment stage, and a quality control stage.

[0084] Material preparation may comprise pre-drying the HDPE pellets and fiber reinforcements to remove moisture and precisely weighing the HDPE, fibers, and additives according to the formulation.

[0085]Compounding may include using a twin-screw extruder for optimal mixing, feeding HDPE pellets into the main hopper, introducing fibers and additives through side feeders at specific points in the extruder, maintaining temperature profile from 180°C to 230°C along the extruder barrel, setting screw speed to 200-300 RPM for thorough mixing without fiber breakage, using a vacuum venting zone to remove any volatile compounds, extruding the compounded material into strands and pelletizing.

[0086]Injection molding includes using a specialized mold designed for pickleballs with provisions for creating holes, and preheating the mold to60-80°C. The injection molding machine parameters may be set to a barrel temperature of 200-240°C (varied across zones), an injection pressure of 80-120 MPa, and a holding pressure of 60-90 MPa. A cooling time of 15-25 seconds (depending on wall thickness) may be imposed before using a hot runner system to maintain material consistency. A sequential valve gate system may be implemented to optimize fiber orientation around holes.

[0087]Post-molding treatment may include allowing balls to cool to room temperature, and, optionally, conducting a brief annealing process which may include heating balls to 70-80°C for 30-60 minutes, and allow the balls to slowly cool to room temperature to relieve internal stresses.

[0088] Quality control may include visual inspection for surface defects and hole uniformity, weight measurement to ensure compliance with regulations, bounce test on a standardized surface, impact resistance test using a controlled drop method, and microscopic examination of cut samples to verify fiber distribution.

[0089]The hole reinforcement may be optimized. For example, some embodiments may implement a variable fiber concentration technique. An example variable fiber concentration technique may include using a higher concentration of fibers (15-20%) in the areas surrounding the holes and maintaining a lower concentration (5-10%) in the ball's core.

[0090] Another technique for variable fiber concentration includes designing a mold with strategically placed gates. Such a mold may position gates to direct fiber flow around hole areas during injection. Flow analysis software can be used to optimize gate locations and injection parameters.

[0091] A multi-shot injection process may be used. A first shot may inject the core material with lower fiber content, and the second shot may inject higher fiber content material around hole areas.

[0092] Thus, according to some embodiments, a pickleball ball according to FIG. 6A and 6B may be formed using a method comprising preparing a composite material by compounding HDPE with short reinforcing fibers in a twin-screw extruder, and injection molding the composite material into a spherical body with a plurality of holes using a mold with strategically placed gates to direct fiber flow around hole areas. The injection molding process may utilize a sequential valve gate system to optimize fiber orientation around said holes. A multi-shot injection process can be used, wherein a first shot injects a core material with a lower fiber content, and a second shot injects a higher fiber content material around hole areas.

[0093] An example mold for creating reinforced pickleball balls of FIGS. 6A-6B may include a spherical cavity for forming a body of the pickleball ball, a plurality of protrusions within said cavity for forming holes in the pickleball ball, a hot runner system with a sequential valve gate system, and gates located strategically to direct the flow of fiber-reinforced plastic material around said holes during the injection molding process.

[0094]FIG. 7 illustrates a pickleball ball 700 with the holes reinforced by harder plastic surrounding the holes, according to some embodiments of the present disclosure. This approach uses a plastic with varying hardness across the ball's structure. The areas immediately surrounding the holes are made with a harder, more crack-resistant plastic, while the rest of the ball maintains the standard flexibility. For example, this may be achieved through a dual-injection molding process or by using a plastic that can be selectively hardened post-molding.

[0095] An example hole 702 is shown with the area 704 immediately surrounding it being shown in a darker shade to indicate a harder plastic than in the areas further out from the holes. In some embodiments, the hardness may be at a gradient such that the hardness of the plastic is lowest at points on the surface that are furthest from nearest holes and increases as it gets nearer to a hole.

[0096] In some embodiments, a dual injection process is used to inject a first harder plastic to a predetermined width from the perimeter of each hole and to inject a second plastic to the rest of the areas of the hollow shell. The second plastic may be an HDPE composite, and the first plastic, for example, may be a high molecular weight HDPE. In some embodiments, the first injection may distribute the same plastic composition to all areas, including in the areas immediately adjacent to the perimeter of the holes, and a second injection may inject a hardening agent to the areas immediately adjacent to the perimeter to cause that area to harden to a greater degree. For example, a hardening nucleating agent may be introduced in the second injection. The gradient of hardening between the areas immediately adjacent to the perimeter and the rest of the hollow shell may be varied depending on the targeted costs of manufacture and the specific surfaces for which the ball is intended. A specialized pickleball ball mold with a gate arrangement similar to that described in relation to FIGS. 6A-6B may be used in the example embodiments of FIGS. 4, 5A-5B, 7 and 8.

[0097]FIG. 8 illustrates a reinforced pickleball ball 800 that comprises reinforced holes where the holes are reinforced on the outside of the hollow shell of the ball, according to some embodiments of the present disclosure.

[0098] In this embodiment, thin, low-profile reinforcement rings 802 are applied to the exterior surface of the ball around each hole (e.g., hole 804). These rings are made of a durable, impact-resistant material and are bonded securely to the ball's surface. The rings are designed to be aerodynamically neutral, maintaining the ball's flight characteristics. This would be flat on the surface to maintain smoothness of the ball.

[0099] The perimeter of the hole is re-enforced to reduce the likelihood of deformation around the holes. This may increase a lifespan of the pickleball ball. Reinforcement on the outside the ball may be easier to manufacture compared with enforcement used inside the ball. The low-profile reinforcement rings 802 around respective holes, as shown in FIG. 8, may extend to varying distances from the perimeter of the respective holes but are separated such that they do not contact each other.

[0100] In some embodiments, a resin is applied to the outer surface of the hollow shell in the area immediately adjacent to each hole. The resin, when cured, forms a strong, rigid bond and applying it to the perimeter of the opening can reinforce the weakest point, making it more resistant to breakage, deformation and wear. The resin can create a smoother, more seamless finish around the opening, preventing debris and moisture from entering and potentially causing damage. Certain types of resin, particularly epoxy resins, offer enhanced durability. The resin can be applied using various techniques, including brushing, spraying, or pouring. The method chosen should ensure proper coverage and penetration. The curing process of the resin should ensure appropriate curing conditions (temperature, humidity, etc.) to achieve the desired level of durability with the specific resin used.

[0101] In some embodiments, the resin may be introduced to the outer surface around the perimeter of each hole before the plastic in the mold has fully cooled. In other embodiments, the resin is added after the ball is removed from the mold. Heat treatment or the like can be used to adhere the resin to the outer surface of the shell in a manner than the uniformity and/or smoothness of the outer surface is not affected.

[0102] Of the example embodiments described in relation to each of FIGS. 4-8, some of the embodiments may have all the pre-made holes of a ball reinforced and some embodiments may have only a subset of the pre-made holes reinforced. The subset may be selected in accordance with desired total weight for the ball, and/or a desired weight distribution. The weight and weight distribution of the ball can be strategically designed to affect the flight behavior (e.g., aerodynamics) and/or surface impact behavior of the ball. For example, the reinforcements can be applied so that each (or most) reinforced ring immediately adjoins only non-reinforced rings, in order to have a lower weight than if all holes were reinforced and have desired aerodynamic behavior upon impact with a paddle or court surface. The edge reinforcements described above in relation to FIGS. 4-8 reinforces a hole such that the reinforcement is entirely or mostly based on the layer of durable material surrounding that hole.

[0103]FIG. 9 illustrates an irregular or random texture pattern on the surface of an example conventional pickleball ball. Different pickleballs manufactured by different manufacturers for indoor and outdoor play have different levels of roughness on the surface of the pickleball. Different levels of roughness create different levels of friction and grit when the ball hits the paddle or the floor, resulting in unpredictable ball behavior. No currently available pickleball balls have an organized and deterministic texture pattern on its surfaces, and most customizations of balls are done in relation to the hole patterns.

[0104] When the pickleball ball surface does not have sufficient grit, the pickleball ball’s bounce from the ground is inconsistent, as there is not enough friction between the ball and the ground. It is difficult to get consistent stokes with spin when the pickleball is hit with a pickleball paddle because pickleball surface does not have sufficient grit when it hits the paddle.

[0105]FIG. 10 illustrates four example deterministic (regular) patterns of texture artifacts on the outer surface of the hollow shell of some pickleball balls, according to some embodiments of the present disclosure. Having a deterministic pattern that creates more grit and friction in a deterministic manner provides more predictable ball behavior. Thus, for example, a pickleball ball having the outer surface of its hollow shell in a grit pattern according to any one of the four deterministic texture patterns shown in FIG. 10 may have a more predictable manner of behaving upon impact on the pickleball paddle or the court surface. A deterministic grit pattern is conducive to achieving enhanced spin, consistency, and control, thereby elevating player performance and enjoyment.

[0106] In some embodiments, the grit material may be silicon carbide (SiC). SiC is an example of a material that provides sufficiently high hardness and wear resistance that can ensure durability under repeated impacts, and also maintains the grit pattern performance over time. The grit particles may be of a particle size of 40-60 mesh (approx. 250-425 microns), to provide an optimal balance between noticeable roughness for increased friction and minimal impact on ball weight and aerodynamics. The grit particle shape may be angular or semi-angular, to create better interlocking with the paddle surface, maximizing friction and spin generation.

[0107] In some embodiments, the grit is applied in a hexagonal grid pattern. The hexagonal grid pattern offers a uniform distribution of grit across the ball surface, promoting consistent spin and control. There may be a spacing of 2mm between grid lines to ensure ample grit coverage without overcrowding the surface, balancing friction and aerodynamics.

[0108] The grit pattern may be bonded to the ball surface using a high-temperature epoxy resin. The epoxy resin provides strong bonding to the ball surface, resisting wear and tear even under intense play. The curing may be performed in a controlled environment with specific temperature and humidity settings, so that uniform adhesion that minimizes potential warping of the ball is ensured, providing consistent performance.

[0109] Before balls formed with the deterministic grit patterns are put into tournament play, a quality control process may be performed. An example quality control process may provide strict control over particle size and shape through supplier selection and incoming inspection to ensure grit consistency. Laser-guided application processes can be used to achieve precise grid placement and minimize irregularities. Regular destructive and non-destructive testing can be performed to verify grit bond strength under playing conditions. Post-application inspection to ensure the ball maintains its spherical shape and complies with official regulations may be performed.

[0110] Performance testing of ball flight, spin, and control assessments can be performed under varying conditions to validate performance benefits. The increased friction between the ball and paddle surface generates more spin, enabling greater shot variety and control. The uniform grit distribution promotes predictable spin response and ball behavior, regardless of impact location. Enhanced grip of the ball surface allows for precise placement and execution of shots, even with subtle paddle movements. Robust grit material and application can withstand repeated impacts, maintaining performance over extended use.

[0111] An example manufacturing process for balls with a deterministic surface grit pattern may include a ball production stage, a grit preparation stage, a grit application stage, and a curing and finishing stage. Ball production may be performed utilizing standard manufacturing techniques to produce high-quality pickleball shells meeting all official regulations for size, weight, and material composition. The process should ensure consistent shell surface smoothness and uniformity for optimal grit adhesion.

[0112] The grit preparation includes procuring silicon carbide grit that adheres to the specified particle size (40-60 mesh) and shape (angular/semi-angular). The high-temperature epoxy resin is prepared according to manufacturer instructions, ensuring proper mixing and degassing for optimal adhesion and curing. The grit can be applied employing a laser-guided application system to precisely apply the epoxy resin to the ball surface in the hexagonal grid pattern.

[0113] The resin application thickness may be controlled to achieve desired grit density and minimize excess material. Immediately after resin application, the SiC grit may be evenly distributed onto the wet resin using a controlled dispensing mechanism. Complete and uniform coverage of the grid pattern with the grit can be ensured avoiding gaps or clumping.

[0114] Curing and finishing can be performed by transferring the grit-coated balls to a controlled environment chamber with pre-set temperature and humidity levels. The epoxy resin is cured according to manufacturer recommendations, ensuring complete bonding of the grit to the ball surface. Upon curing completion, each ball may be inspected for any irregularities in grit adhesion or pattern accuracy. Any excess or loose grit particles are gently removed using a soft brush or compressed air.

[0115]FIG. 11 illustrates a pickleball ball 1100 with the surface area on its outer surface of the hollow shell between holes 1102 having a regular pattern of circular indentations 1104, according to some embodiments of the present disclosure.

[0116] In some embodiments, a multi-pattern in which a second pattern is overlaid over the surface of the ball is used. In such embodiments, the surface has its own friction pattern, and the overlay pattern is an additional layer of pattern on the surface to provide the surface with the more deterministic pattern. Like a golf ball, a deterministic pattern of circular indentations 1104 is overlaid over random surface pattern.

[0117]FIG. 12 illustrates a pickleball ball 1200 with the surface area between holes 1202 having a deterministic pattern of grit 1204, according to some embodiments of the present disclosure. In these embodiments, a layer of grit in a predetermined regular pattern is added to the surface of the ball. The composition of the grit may be as described in relation to FIG. 10. As described above, the deterministic pattern provides for more predictable ball behavior and enhanced spin.

[0118]FIG. 13 illustrates a pickleball ball 1300 with the surface area between holes 1302 having a regular pattern of micro indentations 1304, according to some embodiments of the present disclosure. A pickleball with micro notches manufactured into the plastic to help the ball grip the paddle and ground better. Resulting in more speed, spin and control from strikes.

[0119] Notches could be any type of shape or pattern and could have varying depths and widths. Different materials could be molded into notches, for example, carbon fiber, rubber, gel, etc. In some embodiments, a layer of carbon fiber or other material, similar to pickleball paddle surface, can be molded into notches.

[0120] Pickleball balls of each of the embodiments of FIGS. 11-13 may be formed by incorporating the texture pattern to the outer surface of the ball in a manner similar to that described in relation to FIG. 11.

[0121]FIG. 14 illustrates a pickleball ball 1400 that comprises reinforced holes 1402 and a deterministic patterned surface 1404. A reinforcement ring structure 402 can be used to reinforce the perimeter of each hole for example by attaching to the immediate perimeter 406 of the hole from inside of the hollow shell. The embodiment shown in FIG. 14 is one example of a combination of one of the hole edge reinforcing techniques described in this disclosure with an enhanced surface textures described in this disclosure. Similar to the combination shown in FIG. 14, any one of the hole edge reinforcing techniques described in this disclosure may be combined with any one of the enhanced surface textures described in this disclosure. In one example, a pickleball ball with its holes reinforced is manufactured as described in relation to any of FIGS. 4-8, and a texture is incorporated on to the ball surface as described in relation to any of FIGS. 10-13.

[0122] The above described embodiments provide pickleball balls with improved crack-resistance, certain desired characteristic behaviors (e.g., flight, bounce, spin, grip with paddle, etc.), and/or improved noise suppression. It should be noted that embodiments of the present disclosure are not limited to pickleball balls with the particular construction materials, hole reinforcements, and/or surface texture patterns described in this disclosure. Although various embodiments have been shown and described in detail, the claims are not limited to any particular embodiment or example. For example, respective features described in various embodiments may be combined to form further embodiments in accordance with the present disclosure.