US20020086749A1 - Sportsball and manufacturing method thereof - Google Patents

Abstract

A sportsball includes a ball cover, a bladder disposed in the ball cover, and a stress absorbing layer provided between the ball cover and the bladder. The ball cover has a valve hole provided thereon and consists of a plurality of panels each having a predetermined shape connected edge to edge to form a roundness shape. The bladder includes a rubber bladder ball, an exterior web layer integrally adhered on an outer surface of the bladder ball, and a valve stem which is mounted on the bladder ball and is outwardly extended through the valve hole of the ball cover for air inflation. The stress absorbing layer consists of a plurality of sheets each has a predetermined shape corresponding to the shape of the panel and each sheet is attached to an inner surface of the panel of the ball cover to provide a uniform thickness of the ball cover. Therefore, the stress absorbing layer is adapted for not only increasing a contact area between the bladder and the ball cover but also evenly distributing and absorbing an impact force and a stress applied on the sportsball.

Description

CROSS REFERENCE OF RELATED APPLICATION
• This application is an improvement of a utility application, Pat. No. 5,772,545, patented Jun. 30, 1998 by the inventor of this application.[0001]
BACKGROUND OF THE PRESENT INVENTION
• 1. Field of Invention[0002]
• The present invention relates to sportsballs, and more particularly to a durable sportsball adapted for mass production, wherein the sportsball can retain its spherical shape and distribute an impacting stress throughout the ball.[0003]
• 2. Description of Related Arts[0004]
• Sportsball such as soccer ball and volleyball generally comprises a ball cover and a bladder disposed inside the ball cover. The ball cover, which is preferably made of leather or synthetic leather, has a valve hole provided thereon and consists of a plurality of panels connected edge to edge by machine sewing to form a roundness shape wherein the ball cover is composed of an outer coating, an intermediate layer, and an inner lining layer to strengthen and support the intermediate layer.[0005]
• Accordingly, the sportsball further comprises an exterior web layer integrally adhered on an outer surface of the bladder wherein the web layer has at least an elongating strengthened thread evenly wound around and around the outer surface of the bladder. So, the strengthened thread is overlapped with each other to form the web layer to entirely embrace the bladder for supporting the ball cover and resisting the stress and impact force of the sportsball.[0006]
• Since the panels are edge to edge connected together, the ball cover cannot be formed as a prefect spherical interior such that when the bladder is received in the ball cover, the inflated bladder will not fit into the ball cover in full contact, especially at the edges of the panels of the ball cover. Thus, the edges of the ball cover will affect the roundness of the sportsball.[0007]
• Furthermore, the leather or the thickness and hardened synthetic leather ball cover may make the players feels hurt and pain while contacting the sportsball, especially to children and those training players.[0008]
SUMMARY OF THE PRESENT INVENTION
• A main object of the present invention is to provide a sportsball which comprises a ball cover well supported by a strengthened bladder. Therefore, no additional lining is required to adhere onto the ball cover, so as to lower the material and manufacturing cost of the sportsball.[0009]
• Another object of the present invention is to provide a sportsball which has a stress absorbing layer to reduce the painful during contact, especially suitable for children and training players.[0010]
• Another object of the present invention is to provide a sportsball wherein the bladder has a better flexibility and impact resisting ability.[0011]
• Another object of the present invention is to provide a sportsball wherein the stress absorbing is adapted for fittedly filling a gap between the ball cover and the bladder so as to provide a better roundness of the sportsball.[0012]
• Another object of the present invention is provide a sportsball wherein since the stress is distributed on the stress absorbing layer and the bladder but not the ball cover, the expensive leather panels of the ball cover can be thinner to lessen the cost.[0013]
• Another object of the present invention is to provide a manufacturing method of a sportsball which enables the ball cover to be sewn by sewing machine, and thus it is suitable for mass production.[0014]
• Accordingly, in order to accomplish the above objects, the present invention provides a sportsball, comprising:[0015]
• a ball cover having a valve hole provided thereon and a plurality of panels connected edge to edge to form a roundness shape, wherein each of the panels having a predetermined shape has an outer coating layer, an inner lining layer, and an intermediate layer which is integrally formed between the outer coating layer and the inner lining layer and is strengthened and supported by the inner lining layer;[0016]
• a bladder which is disposed inside the ball cover comprising a bladder ball, an exterior web layer integrally attached on a predetermined area of an outer surface of the bladder ball, and a valve stem which is mounted on the bladder ball and is outwardly extended to an exterior of the ball cover through the valve hole for air inflation, wherein the web layer comprises at least an elongated strengthened thread evenly wound around the outer surface of the bladder ball in such a manner that the strengthened thread is overlapped to form the web layer to entirely embrace the bladder ball for supporting the ball and resisting the stress and impact force applied to the sportsball; and[0017]
• a stress absorbing layer comprising a plurality of absorbing pad having a flexibility ability fittedly attached to the panels respectively for filling up a gap between the ball cover and the bladder, so as to increase the contact area therebetween and reinforce the roundness shape of the sportsball.[0018]
• Thus, the present invention also provides a specific manufacturing method for producing the sportsball, which comprises the steps of:[0019]
• (1). Inflate a bladder ball which has a valve stem provided thereon.[0020]
• (2). Coat at least an elongated strengthened thread such as nylon threads with glue.[0021]
• (3). Wind the strengthened thread evenly around an outer surface of the bladder ball until the bladder ball is embraced by a web layer of the strengthened thread to form a strengthened bladder.[0022]
• (4). Heat the bladder in a mold until the web layer is permanently and rigidly united with the outer surface of the bladder ball.[0023]
• (5). Cut a ball cover material, such as leather or synthetic leather made of foaming PU or PVC sponge material, into a predetermined number of panels in predetermined shape. For soccer ball, 12 pieces of pentagonal panels and 20 pieces of hexagonal panels are cut. For volleyball, 18 pieces of panels in two kinds of rectangular shape are cut.[0024]
• (6). Sew the panels edge to edge together by sewing machine to form a ball cover which has a valve hole provided thereon, wherein a section of panels is remained unsewn to form an inlet opening.[0025]
• (7). Cut a stress absorbing layer into a predetermined number of absorbing pads and shapes corresponding to the panels of the ball cover.[0026]
• (8). Attach the absorbing pads of the stress absorbing layer to the panels of the ball cover.[0027]
• (9). Heat the ball cover and turn the ball cover right side out.[0028]
• (10). Insert the strengthened bladder into the ball cover through the inlet opening.[0029]
• (11). Align and glue the valve stem of the bladder with the valve hole of the ball cover.[0030]
• (12). Semi-inflate the bladder to ensure that the inflated bladder is adapted for propping against the ball cover.[0031]
• (13). Sew the inlet opening of the ball cover together by hand.[0032]
• (14). Fully inflate the sportsball to more than a standard pressure within a shaping mold to ensure a permanent structure and shape of the bladder and the ball cover.[0033]
BRIEF DESCRIPTION OF THE DRAWINGS
• FIG. 1 is a sectional perspective view of a sportsball according to a preferred embodiment of the present invention.[0034]
• FIG. 2 is a partially enlarged sectional view a ball cover of a conventional sportsball.[0035]
• FIG. 3 is a partially enlarged sectional view of the ball cover of the sportsball according to the above preferred embodiment of the present invention.[0036]
• FIG. 4 illustrates a manufacturing method of the sportsball according to the above preferred embodiment of the present invention.[0037]
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
• Referring to FIG. 1 of the drawings, a sportsball according to a preferred embodiment of the present invention is illustrated. The sportsball, such as a soccer ball or a volleyball, comprises a[0038]ball cover20 and a strengthenedbladder30 disposed in theball cover20. The ball cover20 is made of leather or synthetic leather such as polyurethane (PU) or polyvinyl chloride (PVC). The synthetic leather is composed of an outer coating layer21, an intermediate layer22, and an inner lining layer23 to strengthen and support the intermediate layer22, as shown in FIG. 2.
• The leather or synthetic leather is cut into a plurality of[0039]panels24 with predetermined shape. For soccer ball, the most common shape of thepanel24 is pentagon and hexagon. In other words, the ball cover20 of a soccer ball is made of 12 pieces of pentagonal panel and 20 pieces of hexagonal panel sewn edge to edge bysewing threads25. The spherical ball cover20 of a volleyball consists of 18 pieces of rectangular panel sewn edge to edge withsewing threads25. The ball cover has avalve hole26 provided thereon.
• The[0040]inflatable bladder30, which is disposed inside theball cover20, comprises a rubber madebladder31 and avalve stem32 mounted thereon and outwardly extended through thevalve hole26 of the ball cover20 to connect thereto for air inflation. In accordance with the present invention,bladder30 further comprises anexterior web layer33 integrally attached on an outer surface of thebladder ball31. As shown in FIG. 1, thebladder ball31 is entirely embraced by theweb layer33. Theweb layer33 comprises at least an elongated strengthened thread331 (usually a plurality of strengthenedthread331 being applied), such as nylon threads, evenly wound around and around the outer surface of thebladder ball31. Therefore, the strengthenedthread331 is overlapped with each other to form theweb layer33.
• In order to enable the strengthened[0041]thread331 being permanently affixed on the outer surface of thebladder ball31, before winding onto thebladder ball31, the strengthenedthread331 are coated with glue for adhering to the outer surface of thebladder ball31 and each other. Moreover, thebladder ball31 with the adhering strengthenedthread331 thereon are together cured by heating in a mold so that the adhering strengthenedthread331 will be hardened to form theweb layer33 which is permanently united with therubber bladder ball31 integrally.
• Like the fishing net structure or the spider web structure, web structure is one of the most strengthened and rigid construction that can support high stress and resist high impact force. Thus, the[0042]web layer33 highly reinforces the soft and weakrubber bladder ball31. In other words, thebladder30 of the present invention is strengthened by theweb layer33 and has a better flexibility and impact resisting ability.
• Due to the presence of the[0043]valve stem32 on thebladder30, the sportsball may lose balance when it is flowing in air, i.e., the sportsball would fall down with thevalve stem32 always directing downwards. In order to ensure a better balance for the sportsball, arubber pad34 having the same weight of thevalve stem32 is further integrally adhered to an end, which is opposite to thevalve stem32 of thebladder30 in order to symmetrically balance the weight of thebladder30.
• The sportsball further comprises a[0044]stress absorbing layer40 provided between theball cover20 and thebladder30 wherein thestress absorbing layer40 is made of soft, flexible and stress absorbing material such as EVA or foaming PU or PVC. Thestress absorbing layer40 is cut into a plurality of absorbingpads41 each having a predetermined shape corresponding to the shape of thepanel24 of theball cover20. Each absorbingpad41 of thestress absorbing layer40 is attached to an inner surface of therespective panel24 of the ball cover20 preferably by glue. Thestress absorbing layer40 provides various remarkable features as follows.
• When an impact force is applied on the[0045]ball cover20, the major stress is absorbed by thestress absorbing layer40, which can reduce the stress directly on theball cover20 and thebladder30. Therefore, the sportsball is more durable and has a longer life span. Thus, thestress absorbing layer40 provides a cushion effect that can reduce the painful while contacting the sportsball, such as heading for soccer players or spiking for volleyball players, especially suitable for the children and training players.
• Moreover, each absorbing[0046]pad41 of thestress absorbing layer40 has a predetermined height in such a manner that the ball cover20 is adapted for forming a prefect spherical interior to fittedly receive the inflatedbladder30. Since thepanels24 are sewn edge to edge together wherein the edges of thepanels24 are inwardly protruded from theball cover20, the interior of the ball cover20 is not a prefect spherical shape. When air is pumped into thebladder30 through thevalve stem32 in order to prop up theball cover20, the edges of thepanels24 will bias against the outer surface of thebladder ball31 so as to affect the roundness shape of the sportsball. As shown in FIG. 2, the conventional method of connecting thepanels24A of the ball cover20A illustrates that the interior of the ball cover20A is not a prefect spherical shape. A gap is formed between the ball cover20A and thebladder31A since the edges of thepanels24A are inwardly extended from the ball cover20A such that thebladder31A is not in a round shape when it is inflated.
• So, when the absorbing[0047]pads41 of thestress absorbing layer40 are attached on theball cover20, the ball cover20 has a uniform thickness to provide a prefect spherical interior of the ball cover20 for fittedly receiving thebladder30 therein. In other words, when thebladder30 is inflated, a gap is formed between thebladder ball31 and theball cover20. So, thestress absorbing layer40 is attached to the ball cover20 to fittedly fill the gap to increase the contact area between thebladder ball31 and theball cover20, so as to reinforce the roundness shape of the sportsball, as shown in FIG. 3.
• Additional supporting linings of the conventional ball cover can be eliminated. The synthetic leather of each[0048]panel24 of the ball cover20 doest not need to adhere those additional linings to increase its strength. So, the thickness and the hardness of the synthetic leather made ball cover20 can also be reduced, which enable to utilizethinner sewing threads25 to sew thepanels24 together. The manufacturing cost and time can be greatly reduced.
• For leather made[0049]ball cover20, as shown in FIG. 3, since the major stress and impact force is absorbed by thestress absorbing layer40, theexpensive leather panels24 of the ball cover20 can be thinner to lessen the cost. Thus, thestress absorbing layer40 can soften and reinforce theleather ball cover20.
• It is worth to mention that one of the absorbing[0050]pads41 of thestress absorbing layer40 has a valve throughhole42 provided thereon, which is aligned with thevalve hole26 of thepanel24, such that thestem valve32 is adapted for extending outwardly through the valve throughhole42.
• A specific manufacturing method is used to produce the sportsball of the present invention, as illustrated in FIG. 4, which comprises the following steps:[0051]
• (1). Inflate a[0052]bladder ball31 which has avalve stem32 provided thereon.
• (2). Coat at least an elongated strengthened[0053]thread331 such as nylon threads with glue.
• (3). Wind the strengthened[0054]thread331 evenly around an outer surface of thebladder ball31 until thebladder ball31 is embraced by aweb layer33 of the strengthenedthread331 to form a strengthenedbladder30.
• (4). Heat the[0055]bladder30 in a mold M until theweb layer33 is permanently and rigidly united with the outer surface of thebladder ball31.
• (5). Cut a ball cover material, such as leather or synthetic leather made of foaming PU or PVC sponge material, into a predetermined number of[0056]panels24 in predetermined shape. For soccer ball, 12 pieces of pentagonal panels and 20 pieces of hexagonal panels are cut. For volleyball, 18 pieces of panels in two kinds of rectangular shape are cut.
• (6). Sew the[0057]panels24 edge to edge together by sewing machine to form aball cover20 which has avalve hole26 provided thereon, wherein a section of panels is remained unsewn to form aninlet opening28.
• (7). Cut a[0058]stress absorbing layer40 into a predetermined number ofabsorbing pads41 and shapes corresponding to thepanels24 of theball cover20.
• (8). Attach the absorbing[0059]pads41 of thestress absorbing layer40 to thepanels24 of theball cover20.
• (9). Heat the[0060]ball cover20 and turn the ball cover20 right side out.
• (10). Insert the strengthened[0061]bladder30 into the ball cover20 through theinlet opening28.
• (11). Align and glue the[0062]valve stem32 of thebladder30 with thevalve hole26 of theball cover20.
• (12). Semi-inflate the[0063]bladder30 to ensure that the inflatedbladder30 is adapted for propping against theball cover20.
• (13). Sew the inlet opening[0064]28 of the ball cover20 together by hand.
• (14). Fully inflate the sportsball to more than a standard pressure within a shaping mold M′ to ensure a permanent structure and shape of the[0065]bladder30 and ball cover20.
• In step (8), when the[0066]panels24 are sewn together, the absorbingpads41 are fittedly attached to thepanels24 wherein each absorbingpad41 is encircling with the sewn edges of thepanels24 so as to form a prefect spherical shape of the interior of theball cover20. It is worth to mention that the thickness of the absorbingpad41 is the equal to the sewn edge of thepanel24 and the absorbingpad41 can be further trimmed in order to form a uniform thickness of theball cover20.
• As specified above, the[0067]valve stem32 on thebladder30 may cause the sportsball losing balance when it is flowing in air, i.e. the sportsball fall down with thevalve stem32 always directing downwards. The following step can be applied after the above step (3) in order to ensure a better balance for the sportsball:
• (a). Adhere a[0068]rubber pad34 having the same weight of thevalve stem32 integrally to an end, which is opposite to thevalve stem32 of thebladder30 in order to symmetrically balance the weight of thebladder30.
• According to the improved structure of the sportsball of the present invention, the ball cover[0069]20 can be sewn by the sewing machine and thus it is suitable for mass production. Thus, the strengthenedbladder30 can support and retain the ball cover20 in the desire roundness even though thebladder30 is over-inflated up to 15-20% more than the standard pressure of the sportsball. Moreover, the supporting force of thebladder30 applied to the ball cover20 through thestress absorbing layer40 is evenly distributed so that the sportsball can has an even roundness to fulfill most players' desire.
• While the foregoing description and diagram describe the preferred embodiment of the present invention, it should be appreciated that certain obvious modifications, variations, and substitutions may be made without departing from the spirit and scope of the present invention. The process steps need not be preformed exactly in the order as outlined above nor are all the process steps delineated above necessary for practicing the present invention.[0070]

Claims (20)

What is claimed is:

1. A sportsball, comprising:

a ball cover having a valve hole provided thereon and a plurality of panels each having a predetermined shape connected edge to edge to form a roundness shape;

a bladder which is disposed inside said ball cover comprising a bladder ball, an exterior web layer integrally attached on a predetermined area of an outer surface of the bladder ball, and a valve stem which is mounted on said bladder ball and is outwardly extended to an exterior of said ball cover through said valve hole for air inflation, wherein said web layer comprises at least an elongated strengthened thread evenly wound around said outer surface of said bladder ball in such a manner that said strengthened thread is overlapped to form said web layer to entirely embrace said bladder ball for supporting said ball and resisting a stress and impact force applied to said sportsball; and

a stress absorbing layer comprising a plurality of absorbing pad having a flexibility ability fittedly attached to said panels respectively for filling up a gap between said ball cover and said bladder, so as to increase a contact area therebetween and reinforce said roundness shape of said sportsball.

2. A sportsball, as recited inclaim 1, wherein each of said absorbing pad having a predetermined shape corresponding to said panel of said ball cover is attached to an inner surface of said panel for providing a uniform thickness of said ball cover.

3. A sportsball, as recited inclaim 1, wherein each of said panel of said ball cover made of synthetic leather has an outer coating layer, an inner lining layer, and an intermediate layer which is integrally formed between said outer coating layer and said inner lining layer and is strengthened and supported by said inner lining layer.

4. A sportsball, as recited inclaim 2, wherein each of said panels of said ball cover made of synthetic leather has an outer coating layer, an inner lining layer, and an intermediate layer which is integrally formed between said outer coating layer and said inner lining layer and is strengthened and supported by said inner lining layer.

5. A sportsball, as recited inclaim 1, wherein said panels of said ball cover is made of thin leather.

6. A sportsball, as recited inclaim 2, wherein said panels of said ball cover is made of thin leather.

7. A sportsball, as recited inclaim 2, wherein said bladder ball with said strengthened thread thereon are cured together by heating in a mold, so that said adhering strengthened thread is hardened to form said web layer which is permanently united with said outer surface of said bladder ball integrally.

8. A sportsball, as recited inclaim 4, wherein said bladder ball with said strengthened thread thereon are cured together by heating in a mold, so that said adhering strengthened thread is hardened to form said web layer which is permanently united with said outer surface of said bladder ball integrally.

9. A sportsball, as recited inclaim 6, wherein said bladder ball with said strengthened thread thereon are cured together by heating in a mold, so that said adhering strengthened thread is hardened to form said web layer which is permanently united with said outer surface of said bladder ball integrally.

10. A sportsball, as recited inclaim 4, wherein said strengthened thread is a nylon thread.

11. A sportsball, as recited inclaim 6, wherein said strengthened thread is a nylon thread.

12. A sportsball, as recited inclaim 9, wherein said strengthened thread is a nylon thread.

13. A manufacturing method of a sportsball, comprising the steps of:

(a) inflating a bladder ball which has a valve stem provided thereon;

(b) coating at least an elongated strengthened thread with glue;

(c) winding said strengthened thread evenly around an outer surface of said bladder ball until said bladder ball is embraced by a web layer of said strengthened thread to form a strengthened bladder, wherein said overlapped strengthened thread is adhered with each other and to said outer surface of said bladder ball;

(d) heating said bladder in a mold until said strengthened thread hardened to form said web layer which is permanently and rigidly united with said outer surface of said bladder ball;

(e) cutting a ball cover material into a predetermined number of panels in predetermined shape;

(f) sewing said panels edge to edge together by a sewing machine to form a ball cover which has a valve hole provided thereon, wherein a section of said panels is remained unsewn to form an inlet opening;

(g) cut a stress absorbing layer into a predetermined number of absorbing pads each having a predetermined shape corresponding to said panel of said ball cover;

(h) attaching said absorbing pads of said stress absorbing layer to said panels of said ball cover respectively, wherein one of said absorbing pads has a valve through hole provided thereon, which is aligned with said valve hole of said ball cover;

(i) heating said ball cover and turn said ball cover right side out;

(j). inserting said strengthened bladder into said ball cover through said inlet opening;

(k) aligning and gluing said valve stem of said bladder with said valve hole of said ball cover;

(l) semi-inflating said bladder to ensure that said inflated bladder is adapted for propping against said ball cover;

(m) hand sewing said inlet opening of said ball cover together to form said sportsball; and

(n) fully inflating said sportsball to more than a standard pressure within a shaping mold to ensure a permanent structure and shape of said bladder and said ball cover.

14. A manufacturing method of a sportsball, as recited inclaim 13, wherein each of said absorbing pad having a predetermined shape corresponding to said panel of said ball cover is attached to an inner surface of said panel for providing a uniform thickness of said ball cover.

15. A manufacturing method of a sportsball, as recited inclaim 14, wherein each of said panel of said ball cover made of synthetic leather has an outer coating layer, an inner lining layer, and an intermediate layer which is integrally formed between said outer coating layer and said inner lining layer and is strengthened and supported by said inner lining layer.

16. A manufacturing method of a sportsball, as recited inclaim 14, wherein said panels of said ball cover is made of thin leather.

17. A manufacturing method of a sportsball, as recited inclaim 15, wherein said strengthened thread is a nylon thread.

18. A manufacturing method of a sportsball, as recited inclaim 16, wherein said strengthened thread is a nylon thread.

19. A manufacturing method of a sportsball, as recited inclaim 13, after step (c), further comprising an additional step of adhering a rubber pad having a same weight of said valve stem integrally to an end, which is opposite to said valve stem of said bladder in order to symmetrically balance said bladder.

20. A manufacturing method of a sportsball, as recited inclaim 14, after step (c), further comprising an additional step of adhering a rubber pad having a same weight of said valve stem integrally to an end, which is opposite to said valve stem of said bladder in order to symmetrically balance said bladder.

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