Panel structure with foam core and methods of manufacturing articles using the panel structure

A composite head panel of a solid sporting paddle selected from the group consisting of paddle ball paddles, pickle ball paddles, table tennis paddles, and beach paddles, comprising:

• spaced first and second layers of composite material defining an outer periphery having an outer end, opposing sides, and an inwardly tapered handle end extending from the opposing sides, each of the spaced first and second layers having an outer surface and an inner surface facing the inner surface of the other layer;
• a plurality of parallel ribs of composite material extending longitudinally from the outer end to the inwardly tapered handle end, the plurality of parallel ribs connected to and extending between the inner surfaces of the first and second layers and defining a plurality of elongate chambers between the inner surfaces of the first and second layers and each adjacent pair of ribs, the inner surfaces of the first and second layers and opposing inner transverse surfaces of adjacent parallel ribs forming wall surfaces of each elongate chamber;
• a foam core material filling each elongate chamber;
• and
• in a cross-sectional view of the composite head panel, the ribs in a central area inside the opposing sides of the composite head panel have a first transverse thickness between adjacent elongate chambers, and the ribs in an area outside the central area and inside the opposing sides of the composite head panel have a second transverse thickness between adjacent elongate chambers which is less than the first transverse thickness,
• wherein the elongate chambers of the central area include a second width, and the adjacent elongate chambers of the area outside the central area and inside the opposing sides include a first width that is greater than the second width.