Sports paddle and method of manufacture

Abstract

A sports paddle for use in striking an object during play comprises a head including a first base layer and a first support layer. The first base layer has an exposed, first base surface that is configured to contact the object during play, and a first opposed base surface. Additionally, the first base layer is formed from a first material. The first support layer has a first support surface that substantially faces the first opposed base surface. The first support surface is only partially exposed. Additionally, the first support layer is formed from a second material that is different than the first material. The first base surface and the first support surface cooperate to form a first hitting surface that is configured to contact the object during play.

What is claimed is: 
     
         1 . A sports paddle for use in striking an object during play, the sports paddle comprising:
 a head including (i) a first base layer having an exposed, first base surface that is configured to contact the object during play, and a first opposed base surface, the first base layer being formed from a first material; and (ii) a first support layer having a first support surface that substantially faces the first opposed base surface, the first support surface being only partially exposed, the first support layer being formed from a second material that is different than the first material.   
     
     
         2 . The sports paddle of  claim 1  wherein less than approximately twenty percent of the first support surface is exposed. 
     
     
         3 . The sports paddle of  claim 1  wherein the head further includes (i) a second base layer having an exposed, second base surface that is configured to alternatively contact the object during play, and a second opposed base surface, the second base layer being formed from the first material; and (ii) a second support layer having a second support surface that substantially faces the second opposed base surface, the second support surface being only partially exposed, the second support layer being formed from the second material. 
     
     
         4 . The sports paddle of  claim 3  wherein the head further includes a core layer that is coupled to and is positioned substantially between the first support layer and the second support layer. 
     
     
         5 . The sports paddle of  claim 4  wherein the head further includes a first intermediate layer that is positioned substantially between the core layer and the first support layer, and a second intermediate layer that is positioned substantially between the core layer and the second support layer; and wherein each of the first intermediate layer and the second intermediate layer are formed from a carbon fiber material. 
     
     
         6 . The sports paddle of  claim 1  wherein the first base surface and the first support surface cooperate to form a first hitting surface that is configured to contact the object during play. 
     
     
         7 . The sports paddle of  claim 6  wherein the first hitting surface further includes a plurality of first surface features. 
     
     
         8 . The sports paddle of  claim 7  wherein the plurality of first surface features include a plurality of first raised surface features that project outwardly away from the first base layer. 
     
     
         9 . The sports paddle of  claim 8  wherein the plurality of first surface features further include a plurality of first recessed surface features that are formed inwardly into the first base layer. 
     
     
         10 . The sports paddle of  claim 7  wherein the plurality of first surface features include a plurality of first recessed surface features that are formed inwardly into the first base layer. 
     
     
         11 . The sports paddle of  claim 7  wherein the first surface features are formed from the first material. 
     
     
         12 . The sports paddle of  claim 1  wherein the first material includes thermoplastic urethane and the second material includes one or more of a plastic and a viscoelastic material. 
     
     
         13 . The sports paddle of  claim 1  wherein the first base layer includes a plurality of first base apertures that extend through the first base layer, and wherein the first support layer includes a plurality of first support projections that extend at least partially into the first base apertures. 
     
     
         14 . A sports paddle for use in striking an object during play, the sports paddle comprising:
 a head including (i) a first base layer that is configured to contact the object during play, the first base layer including a plurality of first base apertures that extend through the first base layer, the first base layer being formed from a first material; and (ii) a first support layer that is coupled to the first base layer, the first support layer including a plurality of first support projections that extend at least partially into the first base apertures, the first support projections being formed from a second material that is different than the first material.   
     
     
         15 . The sports paddle of  claim 14  wherein the first support projections extend substantially fully into and through the first base apertures. 
     
     
         16 . The sports paddle of  claim 14  wherein the head further includes (i) a second base layer that is configured to alternatively contact the object during play, the second base layer including a plurality of second base apertures that extend through the second base layer; and (ii) a second support layer that is coupled to the second base layer, the second support layer including a plurality of second support projections that extend at least partially into the second base apertures. 
     
     
         17 . The sports paddle of  claim 16  wherein the head further includes a core layer that is coupled to and is positioned substantially between the first support layer and the second support layer. 
     
     
         18 . The sports paddle of  claim 17  wherein the head further includes a first intermediate layer that is positioned substantially between the core layer and the first support layer, and a second intermediate layer that is positioned substantially between the core layer and the second support layer; and wherein each of the first intermediate layer and the second intermediate layer are formed from a carbon fiber material. 
     
     
         19 . The sports paddle of  claim 14  wherein the first base layer and the first support projections cooperate to form a first hitting surface that is configured to contact the object during play. 
     
     
         20 . The sports paddle of  claim 19  wherein the first hitting surface further includes a plurality of first raised surface features that project outwardly away from the first base layer. 
     
     
         21 . The sports paddle of  claim 19  wherein the first hitting surface further includes a plurality of first recessed surface features that are formed inwardly into the first base layer. 
     
     
         22 . A sports paddle for use in striking an object during play, the sports paddle comprising:
 a head including a first hitting surface that is configured to contact the object during play, and a plurality of spaced apart through holes that extend through the first hitting surface, the first hitting surface including a first base layer and a plurality of spaced apart first raised surface features that project outwardly away from the first base layer; and   wherein the first base layer and the first raised surface features are each formed from a first material.   
     
     
         23 . The sports paddle of  claim 22  wherein the first hitting surface further includes a plurality of spaced apart first recessed surface features that are spaced apart from the first raised surface features, the first recessed surface features being formed inwardly into the first base layer. 
     
     
         24 . The sports paddle of  claim 22  wherein the first raised surface features are integrally formed with the first base layer. 
     
     
         25 . The sports paddle of  claim 22  wherein the head further includes a second hitting surface that is configured to alternatively contact the object during play, wherein the plurality of through holes extend through the second hitting surface, the second hitting surface including a second base layer and a plurality of second raised surface features that project outwardly away from the second base layer. 
     
     
         26 . The sports paddle of  claim 22  wherein the first base layer includes an exposed, first base surface that is configured to contact the object during play, and a first opposed base surface; and wherein the head further includes a first support layer having a first support surface that substantially faces the first opposed base surface, the first support surface being only partially exposed, the first support layer being formed from a second material that is different than the first material. 
     
     
         27 . The sports paddle of  claim 26  wherein the first base layer includes a plurality of first base apertures that extend through the first base layer, and wherein the first support layer includes a plurality of first support projections that extend at least partially into the first base apertures. 
     
     
         28 . The sports paddle of  claim 27  wherein the first support projections extend substantially into and through the first base apertures. 
     
     
         29 . The sports paddle of  claim 26  wherein the head further includes a first intermediate layer that is positioned substantially adjacent to the first support layer, the first intermediate layer being formed from a carbon fiber material.