WO2004062734A2

WO2004062734A2 - Ball bat with a strain energy optimized barrel

Info

Publication number: WO2004062734A2
Application number: PCT/US2003/041008
Authority: WO
Inventors: William B. Giannetti; Dewey Chauvin; Hsing-Yen Chuang
Original assignee: Jas D Easton Inc
Current assignee: Jas D Easton Inc
Priority date: 2003-01-03
Filing date: 2003-12-19
Publication date: 2004-07-29
Anticipated expiration: 2005-07-03
Also published as: AU2003300281B2; WO2004062734A3; US20050202909A1; CA2509448A1; AU2003300281A1; JP2006512170A; WO2004062734B1; JP4252538B2; CA2509448C

Abstract

A ball bat includes a barrel having a substantially cylindrical outer wall including a first material located radially outwardly from a neutral axis of the outer wall, and a second material located radially inwardly from the neutral axis of the outer wall. The barrel further includes a substantially cylindrical inner wall located within the outer wall and including a third material located radially outwardly from a neutral axis of the inner wall, and a fourth material located radially inwardly from the neutral axis of the inner wall. The first and third materials each have a specific energy storage in compression of at least 2000 psi, and the second and fourth materials each have a tensile modulus of at least 18 million psi. The ball bat exhibits excellent performance and durability characteristics.

Description

BALL BAT WITH A STRAIN ENERGY OPTIMIZED BARREL

BACKGROUND OF THE INVENTION

Baseball and softball bat manufacturers are continually attempting to develop

ball bats that exhibit increased durability and improved performance characteristics.

Ball bats typically include a handle, a barrel, and a tapered section joining the

handle to the barrel. The outer shell of these bats is generally formed from

aluminum or another suitable metal, and/or one or more composite materials,

Barrel construction is particularly important in modern bat design. Barrels

having a single-wall construction, and more recently, a multi-wall construction, have

been developed. Modern ball bats typically include a hollow interior, such that the

bats are relatively lightweight and allow a ball player to generate substantial "bat

speed" or "swing speed."

Single-wall bats generally include a single tubular spring in the barrel section.

Multi-wall barrels typically include two or more tubular springs, or similar structures,

that may be of the same or different material composition, in the barrel section. The

tubular springs in these multi-wall bats are typically either in contact with one

another, such that they form friction joints, are bonded to one another with weld or

bonding adhesive, or are separated from one another forming frictionless joints. If

the tubular springs are bonded using a structural adhesive, or other structural

bonding material, the barrel is essentially a single-wall construction.

It is generally desirable to have a bat barrel that is durable, while also

exhibiting optimal performance characteristics. Hollow bats typically exhibit a

phenomenon known as the "trampoline effect," which essentially refers to the

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rebound velocity of a ball leaving the bat barrel as a result of flexing of the barrel

wall(s). Thus, it is desirable to construct a ball bat having a high "trampoline effect,"

so that the bat may provide a high rebound velocity to a pitched ball upon contact.

The "trampoline effect" is a direct result of the compression and resulting

strain recovery of the barrel. During this process of barrel compression and

decompression, energy is transferred to the ball resulting in an effective coefficient

of restitution (COR) of the barrel, which is the ratio of the post impact ball velocity to

the incident ball velocity (COR = Vpost impact A/incident). In other words, the

"trampoline effect" of the bat improves as the COR of the bat barrel increases.

Multi-walled bats were developed in an effort to increase the amount of

acceptable barrel deflection beyond that which is possible in typical single-wall

designs. These multi-walled constructions generally provide added barrel deflection,

without increasing stresses beyond the material limits of the barrel materials.

Accordingly, multi-wall barrels are typically more efficient at transferring energy back

to the ball, and the more flexible property of the multi-wall barrel reduces undesirable

deflection and deformation in the ball, which is typically made of highly inefficient

material.

Additionally, a multi-wall bat differs from a single-wall bat because there is no

shear energy transfer through the interface shear control zone(s) ("ISCZ"), i.e., the

region(s) between the barrel walls. As a result of strain energy equilibrium, this

shear energy, which creates shear deformation in a single-wall barrel, is converted

to bending energy in a multi-wall barrel. And since bending deformation is more

efficient in transferring energy than is shear deformation, the walls of a multi-wall bat

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typically exhibit a lower strain energy loss than a single wall design. Thus, multi-wall

barrels are generally preferred over single-wall designs for producing efficient bat-

ball collision dynamics, or a better "trampoline effect."

In a single wall bat, a single neutral axis, which is defined as the centroid axis

about which all deformation occurs, is present for both radial and axial deformations.

The shear stress in the barrel wall is at a maximum, and the bending stress is zero,

along this neutral axis. In a multi-wall bat, an additional independent neutral axis

results from each ISCZ present,, i.e., each wall of a multi-wall barrel includes an

independent neutral axis. As the bat barrel is impacted, each barrel wall deforms

such that the highest compressive stresses occur radially above (i.e., on the impact

side of) the neutral axis, while the highest tensile stresses occur radially below (i.e.,

on the non-impact side of) the neutral axis.

In general, as the wall thickness or barrel stiffness is increased in a bat barrel,

the COR decreases. It is important to maintain a sufficient wall thickness, however,

because the durability of the ball bat typically decreases if the wall(s) are too thin. If

the barrel wall(s) are too thin, the barrel may be subject to denting, in the case of

metal bats, or to progressive material failure, in the case of composite bats. As a

result, the performance and lifetime of the bat may be reduced if the barrel wall(s)

are not thick enough.

The use of composite materials has become increasingly popular in modern

barrel design. The impact and fracture behavior of composite materials is very

complex. Structural composite materials do not undergo plastic deformation, like

metals, but undergo a series of local fractures resulting in a highly complicated

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redistribution of stress. When these resultant stresses exceed a predefined limit,

ultimate breakdown of the structure occurs. It is very difficult, if not impossible, to

accurately predict the initiation^'and progression of failure in these complex structures

based on the behavior of unidirectional laminates in the structure. There is a way,

however, to predict the amount of elastic energy that can be stored per unit mass for

a particular mode of stressing. This is defined as the specific energy storage, which

is the amount of energy that can be stored in a material before the material fails.

The specific energy storage capability of a material for tensile or compression

loading is defined as follows:

ξ = σ_lt7E_ltp

where

ξ = specific energy storage

σ_lt= ultimate longitudinal tensile (or compressive) strength

E_lt = Young's longitudinal tensile (or compressive) modulus

p = density

Thus, a material with high tensile/compressive strength and low modulus and

density will have good energy storage properties.

Elastic materials undergo deformation (i.e., spring like behavior) when

influenced by the application of a force. Under conditions such as impact loading,

when large forces are applied over short periods of time, kinetic energy is

transformed at the elastic material interface into potential energy in the form of

deformation. As a result of entropy, some irreversible losses, in the form of noise

and heat, occur during this energy transfer process.

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When the available kinetic energy of impact is transformed into deformation in

the elastic material, the elastic material releases this stored energy in the form of

kinetic energy iack to^" the impacting body (i.e.; the ball), if it is in contact, and/or the

stored energy is dissipated within the elastic material, if the impacting body is not in

contact with the elastic material. As a result of irreversible energy losses, the elastic

material eventually returns to its original stress-free condition.

The total conservation of energy equation for a bat-ball collision is as follows:

U_Kι_b ⁺ U_K2b = U_K1a + U_K2a + U„ + U_BM + U_MS

where,

U_K1b = ball kinetic energy before impact

U_K2b = bat kinetic energy before impact

U_K1a = ball kinetic energy after impact

U_K2a = bat kinetic energy after impact

U„ = local bat and ball strain energy loss

U_BM = energy loss associated with bat beam modes

U_MS = energy losses associated with heat and noise

(Mustone, Timothy J., Sherwood, James, "Using LS-DYNA to Develop a Baseball

Bat Performance and Design Toot', 6th International LS-DYNA Users Conference,

Detroit, Ml, April 9-10, 2000).

Control and optimization of these losses is important to the design of high

performance durable ball bats, particularly the losses associated with local bat and

ball strain energy. The other losses, such as those associated with heat and noise,

although a significant component in the overall equilibrium equation, are minor in

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comparison to the strain energy losses. Thus, to design a high performance durable

bat, it is desirable to minimize strain energy losses in the barrel of the ball bat.

SUMMARY OF THE INVENTION

The invention is directed to a ball bat that exhibits minimal strain energy

losses associated with bat-ball collisions by employing one or more integral interface

shear control zones in the bat barrel, and/or by the selection and placement of

specific composite materials with respect to the neutral axes in the barrel walls.

In a first aspect, a bat barrel includes a substantially cylindrical outer wall

including a first material located radially outwardly from the neutral axis of the outer

wall, and a second material located radially inwardly from the neutral axis of the

outer wall. The barrel further includes a substantially cylindrical inner wall separated

from the outer wall by an interface shear control zone, and includes a third material

located radially outwardly from the neutral axis of the inner wall, and a fourth

material located radially inwardly from the neutral axis of the inner wall. The first and

third materials each have a specific energy storage in compression of at least 2000

psi, and the second and fourth materials each have a tensile modulus of at least 18

million psi.

In another aspect, the first and third materials each comprise a structural

glass-reinforced epoxy resin.

In another aspect, the second and fourth materials each comprise a graphite-

reinforced epoxy resin.

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In another aspect, at least one of the first, second, third, and fourth materials

comprises a boron-reinforced epoxy resin.

In^'anotlrer aspect, a layer of bond inhibiting material separates the outer wall

from the inner wall. In a related aspect, the outer wall, the inner wall, and the layer

of bond inhibiting material all terminate or blend together at at least one end of the

barrel.

In another aspect, the bat barrel includes a substantially cylindrical outer wall

and a substantially cylindrical inner wall located within the outer wall. The outer wall

and the inner wall blend together at at least one end of the barrel.

In another aspect, the bat barrel includes a substantially cylindrical wall

including a first material located radially outwardly from a neutral axis of the wall,

and a second material located radially inwardly from the neutral axis of the wall. The

first material has a specific energy storage in compression of at least 2000 psi, and

the second material has a tensile modulus of at least 18 million psi.

Further embodiments, including modifications, variations, and enhancements

of the invention, will become apparent. The invention resides as well in

subcombinations of the features shown and described.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, wherein the same reference number indicates the same

element throughout the several views:

_. Fig. 1 is a perspective view of a ball bat.

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Fig. 2 is a perspective partially cutaway view of the ball bat illustrated in Fig.

1.

Fig._.3 is a close up sectional view of Section A of Fig. 1.

Fig. 4 is a diagrammatic view of the barrel cross section illustrated in Fig. 3.

Fig. 5 is a table showing various properties of common composite structural

materials.

DETAILED DESCRIPTION OF THE DRAWINGS

Turning now in detail to the drawings, as shown in Figs. 1 and 2, a baseball or

Softball bat 10, hereinafter collectively referred to as a "ball bat" or "bat," includes a

handle 12, a barrel 14, and a tapered section 16 joining the handle 12 to the barrel

14. The free end of the handle 12 includes a knob 18 or similar structure. The

barrel 14 is preferably closed off by a suitable cap 20 or plug. The interior 19 of the

bat 10 is preferably hollow, which allows the bat 10 to be relatively lightweight so

that ball players may generate substantial bat speed when swinging the bat 10.

The ball bat 10 preferably has an overall length of 20 to 40 inches, more

preferably 26 to 34 inches. The overall barrel diameter is preferably 2.0 to 3.0

inches, more preferably 2.25 to 2.75 inches. Typical bats have diameters of 2.25,

2.69, or 2.75 inches. Bats having various combinations of these overall lengths and

barrel diameters are contemplated herein. The specific preferred combination of bat

dimensions is generally dictated by the user of the bat 10, and may vary greatly

between users.

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The present invention is primarily directed to the ball striking area of the bat

10, which typically extends throughout the length of the barrel 14, and which may

extend partially into the tapered section 16 of the bat^"10. For ease of description,

this striking area will generally be referred to as the "barrel" throughout the

remainder of the description.

As illustrated in Fig. 2, the barrel 14 is made up of one or more substantially

cylindrical layers. The actual shape of each barrel layer may vary according to the

desired shape of the overall barrel structure. Accordingly, "substantially cylindrical"

will be used herein to describe cylindrical barrel layers, as well as other similar barrel

shapes. The barrel 14 preferably includes an outer barrel wall 22 and an inner

barrel wall 24 located within the outer barrel wall 22, each preferably made up of one

or more plies 38 of a composite material. Alternatively, the barrel 14 may include

only a single wall, or may include three or more walls. The barrel wall(s) may

additionally or alternatively be made of one or more metallic materials, such as

aluminum or titanium.

A bond inhibiting layer 30, or a disbonding layer, preferably separates the

outer barrel wall 22 from the inner barrel wall 24. The bond inhibiting layer 30 acts

as an interlaminar shear control zone ("ISCZ") between the outer wall 22 and the

inner wall 24. Accordingly, the bond inhibiting layer 30 prevents shear stresses from

passing between the outer wall 22 and the inner wall 24, and also prevents the outer

wall 22 from bonding to the inner wall 24 during curing of the bat 10, and throughout

the life of the bat 10. Because the bond inhibiting layer 30 acts as an ISCZ, the

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outer barrel wall 22 has a first neutral axis 32, and the inner barrel 24 wall has a

second neutral axis 34, as described above.

The bond-inhibiting layer 30 preferably has a radial thickness of

approximately 0.001 to 0.004 inches, more preferably 0.002 to 0.003 inches. The

bond inhibiting layer is preferably made of a Teflon material, such as FEP

(fluorinated ethylene propylene), ETFE (EthyleneTetrafluoroethylene ), PCTFE

(PolyChloroTriFluoroEthylene), or PTFE (Polytetraflouroethylene), and/or another

material, such as PMP (Polymethylpentene), PVF (Polyvinyl Fluoride), Nylon

(polyamideimide), or Cellophane. Other ISCZs, such as a friction joint, a sliding

joint, or an elastomeric joint, may be used as an alternative to the bond inhibiting

layer 30. The bond inhibiting layer 30, or other ISCZ, may be located at the radial

midpoint of the barrel 14, such that each barrel wall 22, 24 has approximately the

same radial thickness, or it may be located elsewhere in the barrel 14. Thus, the

bond-inhibiting layer 30 is shown at the approximate radial midpoint of the barrel 14

by way of example only.

If the barrel 14 includes three or more walls, a bond-inhibiting layer 30 or

other ISCZ is preferably located between each of the barrel walls, to increase barrel

deflection. Thus, a three-wall barrel preferably includes two bond-inhibiting layers

30 or other ISCZs, a four-wall barrel preferably includes three bond-inhibiting layers

30 or other ISCZs, etc. Alternatively, bond-inhibiting layers 30 or ISCZs may be

located between selected barrel walls only. For ease of description, a two-wall

barrel 14 will be discussed herein, but any other number of barrel walls may be

employed in the ball bat 10.

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In the embodiment illustrated in Figs. 2 and 3, the outer barrel wall 22 and the

inner barrel wall 24 each include a plurality of composite plies 38. The composite

materials^" use^"d^~are^"preferably^"fiber-reinfdrCedrand may include glass,^" graphite,

boron, carbon, aramid, ceramic, kevlar, and/or any other suitable reinforcement

material, preferably in epoxy form. Each composite ply preferably has a thickness of

approximately 0.003 to 0.008 inches, more preferably 0.005 to 0.006 inches. The

overall radial thickness of each barrel wall 22, 24 (including barrel portions on both

sides of the central axis of the bat) is preferably approximately 0.060 inches to 0.100

inches, more preferably 0.075 to 0.090 inches. Optimal selection and placement of

the specific composite materials employed in the ball bat 10 is described in detail

below.

The radial location of the neutral axis in each wall varies according to the

distribution of the composite layers, and the stiffness of the specific layers. Only the

radial components of stress are considered herein, due to their high relative

magnitude in comparison to the axial stresses present. If a barrel wall is made up of

homogeneous isotropoic layers, the neutral axis will be located at the midpoint of the

wall. If more than one composite material is used in a wall, and/or if the material is

not uniformly distributed, the neutral axis may reside at a different radial location.

Thus, the first and second neutral axes 32, 34 are shown at the approximate radial

midpoints of their respective walls 22, 24 by way of example only.

As illustrated in the diagram of Fig. 4, a double-wall barrel structure may be

broken down into four zones, numbered 1 , 2, 3,. and 4. Zones 1 and 3 are the outer

and inner barrel wall compressive stress regions, as they are located above, or

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radially outwardly from (i.e., on the impact side of), their respective neutral axes.

Zones 2 and 4 are the outer and inner barrel wall tensile stress regions, as they are

located below; or radia^'llylnwardϊy from (i.e., on the non-impact side of), their

respective neutral axes.

Materials in compressive zones 1 and 3 are used primarily to increase the

durability of the barrel 14. Materials in tensile zones 2 and 4 are used primarily to

increase the stiffness of the barrel 14, and to substantially match the fundamental

frequencies of the outer and inner barrel walls 22, 24 to minimize energy losses in

the barrel 14. The fundamental frequency of each barrel wall 22, 24 preferably falls

within a constructive coupling range between the walls 22, 24, such that minimal

losses are encountered during the energy transfer from the outer barrel wall 22 to

the inner barrel wall 24. In a preferred embodiment, the fundamental hoop

frequency (i.e., the vibration measured around the diameter of the barrel wall) of the

outer barrel wall 22 is within 20%, more preferably 10%, of the fundamental hoop

frequency of the inner barrel wall 24. The fundametal hoop frequency of each of the

outer and inner walls 22, 24 is preferably in the range of 900 to 2000 Hz, more

preferably 1000 to 1200 Hz.

Various properties of several common structural composite materials are

listed in Table 1 of Fig. 5. High specific energy storage compression materials are

best suited to zones 1 and 3, while high stiffness (i.e., high tensile modulus)

materials are best suited to zones 2 and 4. The composite materials used in zones

1 and 3 define the resultant durability of the structure, while the composite materials

used in zones 2 and 4 adjust the stiffness of the barrel for maximum coupling of

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energy transfer between the outer and inner walls 22, 24. Accordingly, by placing

specific materials in specific zones, the performance and durability of the structure

can be modifie^"dϊndependently^~of ^"one another.

In a preferred embodiment, structural (S) glass-reinforced epoxy resin, or S-

glass epoxy, is used predominantly in zones 1 and 3, due to its extremely high

specific energy storage in compression (approximately 2230 psi). Boron-reinforced

epoxy resin, or boron epoxy, which has a specific energy storage in compression of

approximately 2220 psi, may additionally or alternatively be used in zones 1 and 3.

Other materials having a high specific energy storage in compression may

additionally or alternatively be used in zones 1 and 3. Preferably, the materials used

in zones 1 and 3 have a specific energy storage in compression of at least 2000 psi,

and more preferably, 2200 to 2400 psi. The material(s) used in zone 1 may be the

same, or may differ, from those used in zone 3.

S-glass epoxy may also be utilized in zones 2 and 4, due to its high tensile

specific energy storage (approximately 4790 psi). Indeed, from a durability

standpoint, the entire barrel would benefit from a 100% S-glass multi-wall structure.

S-glass epoxy, however, has a relatively low stiffness, or tensile modulus

(approximately 6.91 million psi). Thus, if S-glass epoxy were used predominantly in

zones 2 and 4, barrel performance would suffer due to a lack of barrel stiffness and

poor energy coupling between the barrel walls 22, 24. Accordingly, graphite-

reinforced epoxy resin, or graphite epoxy, which has a stiffness or tensile modulus of

approximately 20 million psi, is preferably predominantly used in zones 2 and 4, for

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adjusting the stiffness of the barrel. A limited amount of S-glass epoxy may also be

used in zones 2 and 4, however.

3^"dron epoxy,^" which has a stiffness or tensiie modulus ofapproximately 29.6

million psi, may additionally or alternatively be used in zones 2 and 4. Graphite

epoxy is preferred over boron epoxy, however, because the tensile specific energy

storage of graphite epoxy (approximately 1380 psi) is much greater than the tensile

specific energy storage of boron epoxy (approximately 565 psi).

Other materials having a high stiffness or tensile modulus, preferably in

conjunction with a relatively high tensile specific energy storage, may additionally or

alternatively be used in zones 2 and 4. Preferably, the materials used in zones 2

and 4 have a stiffness or tensile modulus of at least 18 million psi, and more

preferably 20 to 30 million psi. The materials used in zones 2 and 4 also preferably

have a tensile specific energy storage of at least 1000 psi, although the stiffness of

the material, which dictates bat performance, is the more significant variable. The

material(s) used in zone 2 may be the same, or may differ, from those used in zone

4.

The layers of selected composite materials may be oriented at various angles

relative to their respective neutral axes 32, 34 to further modify or enhance barrel

performance and durability, and to better match the fundamental frequencies of the

outer and inner barrel walls 22, 24. In a preferred embodiment, each of the

composite plies 38 in zones 1 and 3 is oriented at approximately 50 to 70° relative to

their respective neutral axes 32, 34. Each of the composite plies 38 in zones 2 and

4 is preferably oriented at approximately 20 to 50° relative to their respective neutral

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axes 32, 34. Each ply within a zone may be oriented at the same or different angles

than other plies in that zone. Thus, the location and orientation of specific structural

layers with Tespect torthe ^•lϊeut^'raTaxes allows the barrel durability to be enhanced,

while minimizing strain energy losses in the barrel.

The idea of locating graphite epoxy in the tensile zones (zones 2 and 4) was

not initially intuitive. Previous barrel designs, having graphite epoxy predominantly

located in zones 1 and 3, were subjected to durability tests. When the tests were

concluded, no graphite epoxy fiber failure was witnessed in the compressive zones

(zones 1 and 3) of the barrel. Accordingly, there was no motivation to move the

graphite fibers into the tensile zones, since compressive failure did not appear to

occur in the graphite epoxy fibers.

The graphite epoxy was moved to the tensile zones in the design of a sample

bat according to one embodiment of the present invention, and S-glass epoxy was

used predominantly in the compressive zones. Durability tests were then performed

on the bat, and it was surprisingly discovered that durability increased by a factor of

three (e.g., from approximately 150 ball hits until failure, to approximately 450 ball

hits until failure) over the previous designs.

Thus, while initial analysis did not indicate compressive failure of the graphite

epoxy fibers in the previous bat designs, it is likely that unseen graphite fiber failure

was actually occurring in the compressive zones. In other words, the discovery of a

dramatic increase in bat durability, resulting from moving graphite epoxy fibers to the

tensile zones of the bat barrel, and using S-glass epoxy in the compressive zones of

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the bat barrel, was unexpected, since analysis did not indicate that compressive

fiber failure was occurring in samples constructed following previous designs.

^' The bat^"10 is generally constructed by rolling theNariouslayers of the bat 10

onto a mandrel or similar structure having the desired bat shape. The ends of the

layers are preferably "clocked" or offset from one another so that they do not all end

in the same location before curing. Accordingly, when heat and pressure are

applied to cure the bat 10, the various barrel layers blend together into a distinctive

"one-piece" multi-wall construction. Put another way, all of the layers of the bat are

"co-cured" in a single step, and blend or terminate together at at least one end,

resulting in a single-piece multi-wall structure with no gaps (at the at least one end),

such that the barrel 14 is not made up of a series of tubes, each with a wall

thickness that terminates at the ends of the tubes. As a result, all of the layers act in

unison under loading conditions, such as during striking of a ball.

The blending of the layers into a single-piece multi-wall construction, like tying

the ends of a leaf spring together, offers an extremely durable assembly, particularly

when impact occurs at the extreme ends of the layer separation zones. By blending

the multiple layers together, the barrel 14 acts as a unitized structure where no

single layer works independently of the other layers. One or both ends of the barrel

14 may terminate together in this manner to form the one-piece barrel.

In a preferred embodiment, the bat 10 is constructed as follows. First, the

various layers of the bat 10 are pre-cut and pre-shaped with conventional

machinery. Composite plies 38 used to form the inner wall tensile zone, such as

graphite epoxy, and/or other suitable materials, are rolled onto the bat-shaped

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mandrel. Composite plies 38 used to form the inner wall compressive zone, such as

S-glass epoxy, and/or other suitable materials, are then rolled onto the plies 38 of

^"the iήher wall tensile zone.

A bond-inhibiting layer 30, or other ISCZ layer or material, may then be rolled

onto the plies 38 of the inner wall compressive zone, if such a layer is desired. Next,

composite plies 38 used to form the outer wall tensile zone, such as graphite epoxy,

and/or other suitable materials, are rolled onto the bond-inhibiting layer 30, or onto

the plies 38 of the inner wall compressive section if a bond-inhibiting layer 30 is not

employed. Composite plies 38 used to form the outer wall compressive zone, such

as S-glass epoxy, and/or other suitable materials, are then rolled onto the plies 38 of

the outer wall tensile zone.

As described above, the composite plies 38 are preferably rolled onto the

mandrel such that their ends are offset from another, so that they do not all end in

the same location before curing. Once all of the layers are arranged, heat and

pressure are applied to the layers to cure the bat 10 into a one-piece multi-wall

barreled structure, in which the ends of the layers all terminate together such that

there are no gaps between the barrel walls and the ISCZ. The layers may be

arranged to terminate in this manner at one or both ends of the barrel 14.

The described bat construction, and method of making the same, provides a

bat having excellent "trampoline effect" and durability. These results are primarily

due to the selection and placement of specific materials relative to the neutral axes

in the outer and inner barrel walls 22, 24. Specifically, locating materials having a

high specific energy storage in compression above the neutral axes, and materials

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with a high stiffness or tensile modulus below the neutral axes, yields a durable high

performance ball bat. Additionally, the blending of barrel layers in a single curing

step prδvides δr ihcfeaself durability; 1ϊspecially^"duriήg impact at the extreme ends

of the barrel layers.

Thus, while several embodiments have been shown and described, various

changes and substitutions may of course be made, without departing from the spirit

and scope of the invention. The invention, therefore, should not be limited, except

by the following claims and their equivalents.

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Claims

Express Mail Label No. EV254991383US Patent40095.8003.WO00What is claimed is:

1. A ball bat including a barrel, a handle, and a tapered section joining the

barrel to the ^"handle, with the barrel comprising:

a substantially cylindrical outer wall including a first material located radially

outwardly from a neutral axis of the outer wall, and a second material located radially

inwardly from the neutral axis of the outer wall;

a substantially cylindrical inner wall separated from the outer wall by an

interface shear control zone, the inner wall including a third material located radially

outwardly from a neutral axis of the inner wall, and a fourth material located radially

inwardly from the neutral axis of the inner wall;

wherein the first and third materials each have a specific energy storage in

compression of at least 2000 psi, and the second and fourth materials each have a

tensile modulus of at least 18 million psi.

2. The ball bat of claim 1 wherein the first and third materials each have a

specific energy storage in compression of 2200 to 2400 psi.

3. The ball bat of claim 1 wherein the second and fourth materials each

have a tensile modulus of 20 to 30 million psi.

4. The ball bat of claim 1 wherein the second and fourth materials each

have a tensile specific energy storage of at least 1000 psi.

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5. The ball bat of claim 1 wherein at least one of the first, second, third,

and fourth materials comprises a fiber-reinforced resin composite material.

6. The ball bat of claim 5 wherein the composite material includes at least

one material selected from the group consisting of glass, graphite, boron, carbon,

aramid, and ceramic.

7. The ball bat of claim 1 wherein the first and third materials each

comprise a structural glass-reinforced epoxy resin.

8. The ball bat of claim 1 wherein the second and fourth materials each

comprise a graphite-reinforced epoxy resin.

9. The ball bat of claim 1 wherein at least one of the first, second, third,

and fourth materials comprises a boron-reinforced epoxy resin.

10. The ball bat of claim 1 wherein the interface shear control zone

comprises a layer of a bond inhibiting material separating the outer wall from the

inner wall.

11. The ball bat of claim 10 wherein the bond inhibiting material comprises

at least one material selected from the group consisting of a Teflon®,

polymethylpentene, polyvinyl fluoride, a nylon, and cellophane.

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12. The ball bat of claim 10 wherein the outer wall, the inner wall, and the

^" la er of bond ^"inhibiting material all terminate together at at least one end of the

barrel.

13. The ball bat of claim 1 wherein the interface shear control zone

comprises at least one of a friction joint, a sliding joint, and an elastomeric joint.

14. The ball bat of claim 1 wherein a fundamental hoop frequency of the

outer wall is within 20% of a fundamental hoop frequency of the inner wall.

15. The ball bat of claim 14 wherein the fundamental hoop frequencies of

the outer and inner walls are each in a range of 1000 to 1200 Hz.

16. A ball bat including a barrel, a handle, and a tapered section joining the

barrel to the handle, with the barrel comprising:

a substantially cylindrical outer wall; and

a substantially cylindrical inner wall located within the outer wall, wherein the

outer wall and the inner wall blend together at at least one end of the barrel.

17. The ball bat of claim 16 further comprising an interface shear control

zone separating the outer wall from the inner wall, such that the outer wall is divided

into a first outer section and a first inner section by a first neutral axis, and the inner

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wall is divided into a second outer section and a second inner section by a second

neutral axis.

18. The ball bat of claim 17 wherein the first and second outer sections

each include a material having a specific energy storage in compression of at least

2000 psi, and the first and second inner sections each include a material having a

stiffness of at least 18 million psi.

19. The ball bat of claim 17 wherein the materials in the first and second

outer sections each comprise a structural glass-reinforced epoxy resin.

20. The ball bat of claim 17 wherein the materials in the first and second

inner wall sections each comprise a graphite-reinforced epoxy resin.

21. The ball bat of claim 17 wherein the interface shear control zone

comprises a disbonding layer separating the outer wall from the inner wall.

22. The ball bat of claim 21 wherein the outer wall, the inner wall, and the

disbonding layer all blend together at at least one end of the barrel.

23. A ball bat including a barrel, a handle, and a tapered section joining the

barrel to the handle, with the barrel comprising:

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a substantially cylindrical first wall including a first material located radially

outwardly from a neutral axis of the first wall, and a second material located radially

^"inwardly frόTrrthe^"neutra axls ofthe first Wall;^"

wherein the first material has a specific energy storage in compression of at

least 2000 psi, and the second material has a tensile modulus of at least 18 million

psi.

24. The ball bat of claim 23 further comprising a substantially cylindrical

second wall located within the first wall.

25. The ball bat of claim 24 wherein the second wall is separated from the

first wall by a first interface shear control zone.

26. The ball bat of claim 25 further comprising a substantially cylindrical

third wall located within the second wall.

27. The ball bat of claim 26 wherein the third wall is separated from the

second wall by a second interface shear control zone.

28. A ball bat including a barrel, a handle, and a tapered section joining the

barrel to the handle, with the barrel comprising:

a substantially cylindrical outer wall;

a substantially cylindrical inner wall located within the outer wall;

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an interface shear control zone separating the outer wall from the inner wall,

such that the outer wall is divided into a first outer section and a first inner section by

a first neutral axis, and the inner wall is divided into a second outer section and a

second inner section by a second neutral axis;

wherein the first and second outer sections each include a structural glass

epoxy, and the first and second inner sections each include a graphite epoxy.

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