Cross-Reference to Related Application
[0001] This application is a continuation-in-part (CIP) of
Berggren et al., U.S. Patent Application No. 14/088,850, filed November 25, 2013, and entitled "Sport Ball with Indented Casing," which is a divisional of
Berggren et al., U.S. Patent Application Publication No. 2012/0142465, published on
June 7, 2012, and entitled "Sport Ball with Indented Casing," the entire disclosures of which
are incorporated herein by reference.
Background
[0002] A variety of inflatable sport balls, such as a soccer ball, conventionally exhibit
a layered structure that includes a casing, an intermediate structure, and a bladder.
The casing forms an exterior portion of the sport ball and is generally formed from
a plurality of durable and wear-resistant panels joined together along abutting edge
areas (e.g., with stitching or adhesives). Although panel configurations may vary
significantly, the casing of a traditional soccer ball includes thirty-two panels,
twelve of which have a pentagonal shape and twenty of which have a hexagonal shape.
[0003] The intermediate structure forms a middle portion of the sport ball and is positioned
between the casing and the bladder. Among other purposes, the
intermediate structure may provide a softened feel to the sport ball, impart energy
return, and restrict expansion of the bladder. In some configurations, the intermediate
structure or portions of the intermediate structure may be bonded, joined, or otherwise
incorporated into the casing as a backing material. In other configurations, the intermediate
structure or portions of the intermediate structure may be bonded, joined, or otherwise
incorporated into the bladder.
[0004] The bladder, which has an inflatable configuration, is located within the intermediate
structure to provide an interior portion of the sport ball. In order to facilitate
inflation (i.e., with pressurized air), the bladder generally includes a valved opening
that extends through each of the intermediate structure and casing, thereby being
accessible from an exterior of the sport ball.
[0005] It may be desirable to provide the exterior surface of a sport ball with grooves
or indentations. It may also be desirable to provide such indentations in a
predetermined pattern in order to provide increased performance and to facilitate
manufacturing of the ball.
Summary
[0006] In some embodiments, a sport ball may include indentations in the casing of the ball,
which are arranged to form predetermined patterns in the casing. In some cases, the
patterns may extend across seams to multiple panels. For example, the indentations
may resemble seams between panels of the casing. The indentations may be formed by
compressing and heating a multi-layer casing to join an outer layer to an inner layer
through a foam intermediate layer.
[0007] In one aspect, the present disclosure is directed to a sport ball may incorporate
a casing that includes a plurality of panels joined at a plurality of seams, at least
a first panel of the plurality of panels having (a) a first layer including a polymer
material and positioned to form a portion of an exterior surface of the ball, (b)
a second layer including a polymer foam material and positioned inward and adjacent
to the first layer, and (c) a third layer positioned inward and adjacent to the second
layer, the first panel of the casing defining one or more indentations in the exterior
surface, the first layer being bonded directly to the third layer at the one or more
indentations, wherein the one or more indentations include a first indentation. The
sport ball may also include a bladder located within the casing. In addition, the
first indentation may extend through substantially all of a thickness of the first
panel. Further, the first indentation may have a substantially squared cross-sectional
configuration.
[0008] In another aspect, the present disclosure is directed to a sport ball may incorporate
a casing that includes a plurality of panels joined at a plurality of seams, at least
a first panel of the plurality of panels having (a) a first layer including a polymer
material and positioned to form a portion of an exterior surface of the ball, (b)
a second layer including a polymer foam material and positioned inward and adjacent
to the first layer, and (c) a third layer positioned inward and adjacent to the second
layer, the first panel of the casing defining one or more indentations in the exterior
surface, the first layer being bonded directly to the third layer at the one or more
indentations, wherein the one or more indentations include a first indentation The
sport ball may also include a bladder located within the casing. In addition, the
first indentation may be spaced from the seams. Further, the first indentation may
extend through substantially all of a thickness of the first panel. Also, the third
layer may include an interior surface facing toward the interior of the ball, the
interior surface having a substantially planar configuration opposite the first indentation
in the exterior surface of the first panel.
[0009] In another aspect, the present disclosure is directed to a sport ball may include
a casing formed of a plurality of panels joined together at a plurality of seams,
the plurality of panels including a first panel and a second panel joined to the first
panel at a seam. The ball may also include a bladder located within the casing. Further,
the first panel may include (a) a first outer layer that defines a first indentation
in a first exterior surface of the first panel, (b) a first inner layer that defines
a first interior surface of the first panel, and (c) a first central layer, a majority
of the first outer layer of the first panel being spaced from the first inner layer
of the first panel by the first central layer, and the first outer layer of the first
panel being directly bonded to the first inner layer of the first panel at the first
indentation. The second panel may include (a) a second outer layer that defines a
second indentation in a second exterior surface of the second panel,
(b) a second inner layer that defines a second interior surface of the second panel,
and
(c) a second central layer, a majority of the second outer layer of the second panel
being spaced from the second inner layer of the second panel by the second central
layer, and the second outer layer of the second panel being directly bonded to the
second inner layer of the second panel at the second indentation. The first indentation
may extend proximate to the seam and the second indentation extends proximate to the
seam. In addition, the first indentation may be configured to correspond with the
second indentation across the seam.
[0010] The advantages and features of novelty characterizing aspects of the invention are
pointed out with particularity in the appended claims. To gain an improved understanding
of the advantages and features of novelty, however, reference may be made to the following
descriptive matter and accompanying figures that describe and illustrate various configurations
and concepts related to the invention.
Figure Descriptions
[0011] The invention can be better understood with reference to the following drawings and
description. The drawings are schematic and, therefore, the components in the figures
are not necessarily to scale, emphasis instead being placed upon illustrating the
principles of the invention. Moreover, in the figures, like reference numerals designate
corresponding parts throughout the different views.
Fig. 1 is a perspective view of a sport ball.
Fig. 2 is another perspective view of the sport ball.
Fig. 3 is a cross-sectional view of the sport ball, as defined by section line 3 in
Fig. 2.
Fig. 4 is a top plan view of a panel of the sport ball.
Fig.5 is a bottom plan view of the panel.
Fig.6 is a cross-sectional view of the panel, as defined by section line 6 in Figs.
4 and 5.
Figs. 7A-7F are top plan views corresponding with Fig. 4 and depicting further configurations
of the panel.
Figs. 8A-8F are cross-sectional views corresponding with Fig. 6 and depicting further
configurations of the panel.
Figs. 9A-9C are schematic perspective views of a process for forming the panel.
Figs. 10A-10C are cross-sectional views of the process for forming the panel, as respectively
defined by section lines 10A-10C in Figs. 9A-9C.
Fig. 1 1 is a perspective view of another sport ball.
Fig. 12 is a cross-sectional view, as defined by section line 12 in Fig. 1 1.
Fig. 13 is a schematic illustration of a portion of a casing, including two joined
panels having indentations that form a pattern across the seam between the two panels.
Fig. 14 is a schematic illustration of a portion of a casing, including two joined
panels having indentations having the configuration shown in Fig. 7D.
Detailed Description
[0012] The following discussion and accompanying figures disclose various sport ball configurations
and methods relating to manufacturing of the sport balls. Although the sport ball
is discussed and depicted in relation to a soccer ball, concepts associated with the
configurations and methods may be applied to various types of inflatable sport balls.
In addition to soccer balls, therefore, concepts discussed herein may be incorporated
into basketballs, footballs (for either American football or rugby), volleyballs,
and water polo balls, for example. A variety of non-inflatable sport balls, such as
baseballs and softballs, may also incorporate concepts discussed herein.
Accordingly, the concepts disclosed herein may apply to a wide variety of sport balls.
[0013] For purposes of this disclosure, the term "fixedly attached" shall refer to two components
joined in a manner such that the components may not be readily separated (for example,
without destroying one or both of the components). Exemplary modalities of fixed attachment
may include joining with permanent adhesive, rivets, stitches, nails, staples, welding
or other thermal bonding, and/or other joining techniques. In addition, two components
may be "fixedly attached" by virtue of being integrally formed, for example, in a
molding process.
[0014] As utilized herein, the term "welding" or variants thereof (such as "thermal bonding")
is defined as a technique for securing two elements to one another that involves a
softening or melting of a polymer material within at least one of the elements such
that the materials of the elements are secured to each other when cooled.
Similarly, the term "weld" or variants thereof (e.g., "thermal bond") is defined as
the bond, link, or structure that joins two elements through a process that involves
a softening or melting of a polymer material within at least one of the elements such
that the materials of the elements are secured to each other when cooled.
[0015] As examples, welding may involve (a) the melting or softening of two panels that
include polymer materials such that the polymer materials from each panel intermingle
with each other (e.g., diffuse across a boundary layer between the polymer materials)
and are secured together when cooled and (b) the melting or softening a polymer material
in a first panel such that the polymer material extends into or infiltrates the structure
of a second panel (e.g., infiltrates crevices or cavities formed in the second panel
or extends around or bonds with filaments or fibers in the second panel) to secure
the panels together when cooled. Welding may occur when only one panel includes a
polymer material or when both panels include polymer materials. Welding generally
produces a heat affected zone in which the materials of the two joined components
are intermingled. For purposes of this disclosure, this heat affected zone shall be
considered a "weld" or "thermal bond."
[0016] Additionally, welding does not generally involve the use of stitching or adhesives,
but involves directly bonding components to each other with heat. In some situations,
however, stitching or adhesives may be utilized to supplement the joining of components
through welding.
[0017] In some embodiments, sport ball casings may be formed of a plurality of panels. The
panels may be joined to each other using welding to form the seams between the casing
panels. As with traditional stitching of sport ball panels, the peripheral edges of
the panels may be folded to form flange portions. The flange portions of adjacent
panels may be welded to one another in a similar position as panels of a sewn ball
casing. The majority of the seams may be formed by welding the panels to one another,
forming the casing inside out. Once the majority of the seams are welded, the casing
may be turned right side out through an opening between two or more panels that are
not joined together. After the casing has been turned right side out, additional components
may be inserted into the casing. For example a bladder configured to retain a pressurized
gas may be inserted into the casing. In addition, an intermediate layer having a limited
degree of stretch may be inserted between the bladder and the casing. General procedures
for manufacturing a sport ball with welded seams may be performed as disclosed in
Raynak et al., U.S. Patent Application Publication No. 2010/0240479, published on
September 23, 2010, and entitled "Sport Ball Casing and Methods of Making the Casing," the entire disclosure
of which is incorporated herein by reference.
[0018] One advantage of utilizing a welding process to form the seams relates to the overall
mass of the ball. Whereas approximately ten to fifteen percent of the mass of a conventional
sport ball may be from the seams between panels, welding casing panels to one another
to form the seams may reduce the mass by eliminating stitching and/or adhesives from
the seam. The mass that would otherwise be imparted by the stitching and/or adhesives
may be utilized for other structural elements that enhance the performance properties
(e.g., energy return, sphericity, mass distribution, durability, aerodynamics) of
the ball. Another advantage relates to manufacturing efficiency. Stitching each of
the seams of a conventional sport ball may be a relatively time- consuming process,
particularly when hand stitching is utilized. By welding panels together to form the
seams between panels, the time necessary for forming the casing may be reduced, thereby
increasing the overall manufacturing efficiency.
[0019] In some embodiments, sport ball casing panels may include a polymer material that
may be utilized to secure the panels to each other. Examples of suitable polymer materials
for the casing may include thermoplastic and/or thermoset polyurethane, polyamide,
polyester, polypropylene, and polyolefin. In some configurations, the casing may incorporate
filaments or fibers that reinforce or strengthen the casing. In further configurations,
casing 20 may have a layered structure that includes an outer layer of the polymer
material and an inner layer formed from a textile, polymer foam, or other material
that is bonded with the polymer material.
[0020] When exposed to sufficient heat, the polymer materials within the casing panels transition
from a solid state to either a softened state or a liquid state, particularly when
a thermoplastic polymer material is utilized. When sufficiently cooled, the polymer
materials then transition back from the softened state or the liquid state to the
solid state. Based upon these properties of polymer materials, welding processes may
be utilized to form a weld that joins peripheral portions of panels to each other.
General Sport Ball Configuration
[0021] A sport ball 10 having the general configuration of a soccer ball is depicted in
Figs. 1 -3. Ball 10 exhibits a layered structure having (a) a casing 20 that forms
an exterior portion of ball 10, (b) an intermediate structure 30 located within casing
20, and (c) an inflatable bladder 40 that forms an interior portion of ball 10. Upon
pressurization, bladder 40 induces ball 10 to take on a substantially spherical shape.
More particularly, pressure within bladder 40 causes bladder 40 to place an outward
force upon
intermediate structure 30. In turn, intermediate structure 30 places an outward force
upon casing 20. In order to limit expansion of bladder 40 and also limit tension in
casing 20, a portion of intermediate structure 30 may have a limited degree of stretch.
In other words, bladder 40 places an outward force upon intermediate structure 30,
but the stretch characteristics of intermediate structure 30 effectively prevent the
outward force from inducing significant tension in casing 20. Accordingly, intermediate
structure 30 restrains pressure from bladder 40, while permitting outward forces to
induce a spherical shape in casing 20, thereby imparting a spherical shape to ball
10.
[0022] Casing 20 is formed from various panels 21 that are joined together along abutting
side or edge areas to form a plurality of seams 22. Although panels 21 are depicted
as having the shapes of twelve equilateral pentagons, panels 21 may have non-equilateral
shapes, concave or convex edges, or a variety of other shapes (e.g., triangular, square,
rectangular, hexagonal, trapezoidal, round, oval, non-geometrical) that combine in
a tessellation-type manner to form casing 20. In some configurations, ball 10 may
have twelve pentagonal panels 21 and twenty hexagonal panels 21 to impart the general
configuration of a traditional soccer ball. Selected panels 21 may also be formed
of unitary (i.e., one piece) construction with adjacent panels 21 to form bridged
panels that reduce the number of seams 22. Although seams 22 may be formed by joining
the abutting edge areas of panels 21 with stitching (e.g., hand or machine stitching),
seams 22 may also be formed through adhesive bonding or welding. An example of welded
seams is disclosed in
U.S. Patent Application Publication 2010/0240479 to Raynak, et al., which is incorporated herein by reference.
[0023] Casing 20 defines an exterior surface 23 and an opposite interior surface 24. Exterior
surface 23 faces outward and forms an exterior surface of ball 10. Interior surface
24 is located opposite exterior surface 23 and faces inward and toward intermediate
structure 30. In many configurations of ball 10, interior surface 24 contacts intermediate
structure 30. A plurality of indentations 25 and 26 are formed in casing 20 and extend
toward a central area of casing 20, as depicted in Figs. 1 -3. Whereas indentations
25 are formed in exterior surface 23, indentations 26 are formed in interior surface
24. Indentations 25 are generally located opposite indentations 26.
[0024] Indentations 25 and 26 impart various advantages to ball 10. For example, indentations
25 may have a design or appearance that enhances the aesthetics of ball 10. In some
configurations, indentations 25 may also form indicia identifying the manufacturer
of ball 10 or conveying information as to the features of ball 10. Additionally, indentations
25 may enhance the aerodynamics of ball 10 or provide an individual with greater control
over ball 10 during kicking, dribbling, or passing, for example.
[0025] Intermediate structure 30 is positioned between casing 20 and bladder 40 and may
be formed to include one or more of a compressible foam layer that provides a softened
feel to the sport ball, a rubber layer that imparts energy return, and a restriction
layer to restrict expansion of bladder 40. The overall structure of intermediate structure
30 may vary significantly. As an example, the restriction layer may be formed from
(a) a thread, yarn, or filament that is repeatedly wound around bladder 40 in various
directions to form a mesh that covers substantially all of bladder 40, (b) a plurality
of generally flat or planar textile elements stitched together to form a structure
that extends around bladder 40, or (c) a plurality of generally flat or planar textile
strips that are impregnated with latex and placed in an overlapping configuration
around bladder 40. As another example, intermediate structure 30 may be formed as
a substantially seamless and curved (e.g., hemispherical or spherical) textile, as
disclosed in
U.S. Patent Application Publication 2009/0325746 to Raynak, et al., which is incorporated herein by reference. In some configurations of ball 10, intermediate
structure 30 or portions of intermediate structure 30 may also be bonded, joined,
or otherwise incorporated into bladder 40, or intermediate structure 30 may be absent
from ball 10. Accordingly, the structure of intermediate structure 30 may vary significantly
to include a variety of configurations and materials.
[0026] Bladder 40 has an inflatable configuration and is located within intermediate structure
30 to provide an inner portion of ball 10. When inflated, bladder 40 exhibits a rounded
or generally spherical shape. In order to facilitate inflation, bladder 40 may include
a valved opening (not depicted) that extends through intermediate structure 30 and
casing 20, thereby being accessible from an exterior of ball 10, or bladder 40 may
have a valveless structure that is semi-permanently inflated. Bladder 40 may be formed
from a rubber or carbon latex material that substantially prevents air or other fluids
within bladder 40 from diffusing to the exterior of ball 10. In addition to rubber
and carbon latex, a variety of other elastomeric or otherwise stretchable materials
may be utilized for bladder 40. Bladder 40 may also have a structure formed from a
plurality of joined panels, as disclosed in
U.S. Patent Application Publication 2009/0325745 to Rapaport, et al., which is incorporated herein by reference.
Panel Configuration
[0027] An individual panel 21 is depicted in Figs. 4-6 and has a layered structure that
includes a first or outer layer 51, a second or middle layer 52, and a third or inner
layer 53. Outer layer 51 forms a portion of exterior surface 23, middle layer 52 is
positioned inward and adjacent to outer layer 51, and inner layer 53 is positioned
inward and adjacent to middle layer 52. In this configuration, middle layer 52 is
positioned between layers 51 and 53. That is, layers 51 and 53 effectively form cover
layers (i.e., outer and inner layers) located on opposite sides of middle layer 52.
[0028] A variety of materials may be utilized for each of layers 51 -53, including various
polymer materials, polymer foam materials, and textiles. More particularly, outer
layer 51 may be formed from polymer materials that impart a durable and wear- resistant
exterior surface for ball 10. Examples of suitable polymer materials for panels 21
include polyurethane, polyvinylchloride, polyamide, polyester, polypropylene, and
polyolefin. In some configurations, outer layer 51 may be formed from a synthetic
leather material. Middle layer 52 may be formed from a polymer foam material, such
as polyurethane or ethylvinylacetate. In some configurations, middle layer 52 may
include layers (e.g., three layers) of polymer foam material having different densities.
Additionally, inner layer 53 may be formed from a textile material (e.g., a woven
or knit textile). More particularly, the textile material of inner layer 53 may formed
from polyester, cotton, nylon, rayon, silk, spandex, or a variety of other materials.
The textile material may also include multiple materials, such as a polyester and
cotton blend. In some configurations, one or more layers 51 -53 may incorporate filaments
or fibers that reinforce or strengthen casing 20.
[0029] Layers 51 and 53 are generally spaced from each other by middle layer 52. In the
areas of indentations 25 and 26, however, layers 51 and 53 bow inward and are bonded
or otherwise secured to each other. That is, indentations 25 and 26 are located opposite
each other and extend into panel 21 at corresponding locations, where the portions
of layers 51 and 53 that respectively form indentations 25 and 26 are secured to each
other. In some embodiments, layers 51 and 53 may be thermal bonded to one another.
Whereas a majority of outer layer 51 is spaced from inner layer 53, layers 51 and
53 extend through middle layer 52 in the areas of indentations 25 and 26 to bond or
otherwise be secured to each other. As such, middle layer 52 may part, form an aperture,
or otherwise be absent in the areas of indentations 25 and 26. In some configurations,
middle layer 52 may compress significantly in the areas of indentations 25 and 26,
thereby forming a polymer layer that separates the portions of layers 51 and 53 that
form indentations 25 and 26.
[0030] The positions of indentations 25 and 26 relative to panel 21 may vary considerably.
As depicted, indentations 25 and 26 extend parallel to a plurality of edges 27 of
panel 21. In this configuration, indentations 25 and 26 form a pentagonal shape that
is spaced inward from edges 27. In further configurations of panel 21, however, indentations
25 and 26 may be located in other areas or may impart different shapes or arrangements.
For example, Fig. 7A depicts a configuration wherein indentations 25 form concentric
pentagons that are connected by radial portions. In Figs. 7B and 7C, indentations
25 respectively have circular and triangular configurations, but may also be square,
rectangular, hexagonal, or any other regular or non-regular shape. Referring to Fig.
7D, indentations 25 exhibit a radial configuration. In some configurations, indentations
25 may have a graphic appearance, as in Fig. 7E, or may impart information, as in
Fig. 7F. Moreover, indentations 25 may also form the shape of a company logo or trademark.
As discussed above, indentations 25 may have a design or appearance that enhances
the aesthetics of ball 10, form indicia identifying the manufacturer of ball 10, convey
information as to the features of ball 10, enhance the aerodynamics of ball 10, or
provide an individual with greater control over ball 10.
These advantages may be incorporated into ball 10 by varying the shapes and arrangements
of indentations 25 and 26.
[0031] In some embodiments, the indentations may be spaced from the seams of the sport ball.
This may facilitate manufacturing by providing substantially smooth surfaces at the
peripheral edges of the panels that are joined to one another. In addition, spacing
the indentations from the seams may provide performance benefits, such as aerodynamics
and ball feel. Figs. 7A-7C, 7E, and 7F illustrate configurations in which indentations
25 are spaced from seams 22. (See also, Figs. 1 -5.)
[0032] In some embodiments, the indentations may extend to edges of the panels. This may
facilitate manufacturing, since multiple panels may be indented
simultaneously, for example, by indenting a sheet of casing material, and then cutting
the sheet into a plurality of panels. This may also enable patterns to be carried
across multiple panels, bridging seams between the panels. Fig. 7D illustrates a configuration
in which indentations 25 extend to peripheral edges of panel 21.
[0033] The specific configuration of indentations 25 and 26 may also vary considerably.
Referring to Fig. 6, indentations 25 and 26 each have a generally rounded configuration
that extends to an approximate midpoint of panel 21. In another configuration, as
depicted in Fig. 8A, indentations 25 may extend through more of the thickness of panel
21 than indentations 26. Referring to Fig. 8B, indentations 25 extend through substantially
all of the thickness of panel 21. As also shown in Fig. 8B, in some embodiments, interior
surface 24 of inner layer 53 may have a substantially planar configuration opposite
indentation 25 in exterior surface 23 of panel 21.
[0034] Referring to Fig. 8C, indentations 25 and 26 may be spaced from each other such that
a portion of middle layer 52 extends between indentations 25 and 26. In this configuration,
middle layer 52 has (a) a first thickness between indentations 25 and 26 and (b) a
second thickness in an area spaced from indentations 25 and 26, the first thickness
being less than the second thickness.
[0035] As opposed to rounded, indentations 25 and 26 may also exhibit substantially squared
configurations. For example, in some embodiments, the indentations may have substantially
squared cross-sectional configurations. Such substantially squared cross-sectional
configurations, may have a more distinct appearance than indentations having substantially
rounded cross-sectional configurations. In addition, substantially squared indentations
may also provide performance benefits such as aerodynamics, ball feel, and water channeling.
[0036] In some embodiments, panel 21 may include two opposing indentations having substantially
squared cross-sectional configurations, as depicted in Fig. 8D. In some embodiments,
panel 21 may include a substantially-squared indentation on only one side. For example,
as shown in Fig. 8E, indentation 25 may extend through substantially all of a thickness
of panel 21. Also, as further shown in Fig. 8E, interior surface 24 of inner layer
53 may have a substantially planar configuration opposite indentation 25 in exterior
surface 23 of panel 21.
[0037] Accordingly, outer layer 51 may be bonded (e.g., thermal bonded) to inner layer 53
of the casing panel 21 in a bonded region 28. In some
embodiments, a shoulder 29 of outer layer 51 may have a minimal radius, as shown in
Fig. 8E. In other embodiments, a larger radius may be used at shoulder 29, as shown
in Fig. 8F, in which indentation 25 also has a substantially squared cross-sectional
configuration. The use of a minimal radius or a larger radius shoulder may be selected
to facilitate manufacturing as well as for performance reasons, such as aerodynamics
and ball feel.
[0038] Based upon the above discussion, panels 21 incorporate indentations 25 and 26, which
may have a design or appearance that enhances the aesthetics of ball 10. In some configurations,
indentations 25 may also form indicia identifying the manufacturer of ball 10 or conveying
information as to the features of ball 10. Additionally, indentations 25 may enhance
the aerodynamics of ball 10 or provide an individual with greater control over ball
10 during kicking, dribbling, or passing, for example.
Manufacturing Process
[0039] A variety of manufacturing processes may be utilized to form indentations 25 and
26 in panels 21. An example of a manufacturing process is depicted in Figs. 9A-9C
and 10A-10C. Referring to Figs. 9A and 10A, one of panels 21 is located on a platen
61. A press plate 62 is positioned above platen 61 and includes a protrusion 63 having
a pentagonal shape (e.g., a shape of indentations 25 and 26). Press plate 62 then
translates toward platen 61 and compresses panel 21, as depicted in Figs. 9B and 10B.
More particularly, protrusion 63 presses into and heats the areas of panel 21 forming
indentations 25 and 26. As such, press plate 62 and protrusion 63 (a) soften a portion
of middle layer 52, which may be formed form a polymer foam material and (b) bond
outer layer 51 to inner layer 53. As depicted in Figs. 9C and 10C, press plate 62
then moves away from panel 21 to substantially complete the formation of indentations
25 and 26.
[0040] When exposed to sufficient heat, the polymer materials within panels 21 transition
from a solid state to either a softened state or a liquid state, particularly when
a thermoplastic polymer material is utilized. When sufficiently cooled, the polymer
materials then transition back from the softened state or the liquid state to the
solid state. Based upon these properties, (a) the polymer material of outer layer
51 may soften to form a bond with the textile material of inner layer 53 and (b) the
polymer foam material of middle layer 52 may melt, soften, part, collapse, or form
an aperture that permits layers 51 and 53 to contact and bond with each other.
[0041] In order to properly heat the materials within panel 21, bonding apparatus 62 may
emit heat when in contact with panel 21. In some configurations, resistive heating
elements may be incorporated into pres plate 62 to raise the temperature of panel
21 in the areas of indentations 25 and 26. Alternately, high-frequency (HF) heating,
radio frequency (RF) heating, or ultrasonic heating elements may be incorporated into
press plate 62 and protrusion 63 to raise the temperature of panel 21 in the areas
of indentations 25 and 26.
[0042] As an additional matter, the process disclosed above depicts protrusion 63 as pressing
into one side of panel 21. That is, protrusion 63 presses into the side of panel 21
that includes outer layer 51. Although press plate 62 compresses outer layer 51 against
inner layer 53, which lies against platen 61, indentation 26 forms in inner layer
53. More particularly, outer layer 51 is effectively placed in tension by the pressure
from press plate 62. When the pressure from press plate 62 is removed, the tension
in outer layer 51 pulls inner layer 53 toward the center of panel 21. Although protrusion
63 only presses into one side of panel 21, both indentations 25 and 26 are formed
due to an equalization of forces in panel 21. Accordingly, both of indentations 25
and 26 may be formed by pressing into only one side of panel 21 with press plate 62.
Further Sport Ball Configurations
[0043] Another sport ball 70 is depicted in Figs. 1 1 and 12 as including a casing 71, an
intermediate structure 72, and a bladder 73. As with panels 21 of casing 20, casing
71 has a layered configuration that includes an outer layer 81, a middle layer 82,
and an inner layer 83. Additionally, layers 81 and 83 respectively form indentations
74 and 75 in areas of casing 71. Whereas casing 20 included various panels 21 that
were joined by seams 22, casing 71 has a substantially uniform or unbroken configuration
that does not include panels or includes fewer panels. In order to impart the appearance
of seams similar to seams 22, however, indentations 74 and 75 are located in areas
that correspond with the positions of seams 22 in ball 10. That is, indentations 74
and 75 impart the appearance of seams in ball 70.
[0044] In some embodiments, indentations in adjacent panels may be arranged to correspond
with one another across the seams between the adjacent panels. In some embodiments,
the indentations may extend proximate the seam on adjacent panels. In some cases,
the indentations may extend to the edge of the panel, and thus continue across the
seam. In some embodiments, the indentations of adjacent panels may be arranged to
form a pattern, such as polygonal shapes. Further, the indentations may be arranged
to continue a pattern of the seams between panels. For example, in some embodiments,
the indentations may be aligned with seams. In some cases such indentations may be
configured to define simulated panels of the casing. That is, by having the appearance
of seams, indentations in the casing may be arranged to define portions of a panel
that have the appearance of an entire panel. Further, in some embodiments, the indentations
may be arranged in the pattern of a logo.
[0045] Fig. 13 shows a portion of a sport ball casing 1300. Casing 1300 may be formed of
a plurality of panels, including a first panel 1305 and a second panel 1310. First
panel 1305 may be joined to second panel 1310 at a seam 1325. Seam 1325 may be formed
using any suitable method of joining first panel 1305 and second panel 1310. Exemplary
such methods include stitching, use of adhesives, and welding.
[0046] As shown in Fig. 13, first panel 1305 may include a first central panel portion 1315
and first flange areas 1320 at the peripheral edges of first panel 1305. Similarly,
second panel may include a second central panel portion 1321 and second flange areas
1322. The flange areas may be joined to flange areas of other panels to form casing
1300 by forming seams, such as seam 1325.
[0047] First panel 1305 may include a first indentation 1330, a second indentation 1331
, and a third indentation 1332. In some embodiments, first panel 1305 may include
indentations arranged to form a logo 1355. Portions of first indentation 1330 may
have an elongate configuration and may extend proximate to seam 1325. In some
embodiments, first indentation 1330 may define a pattern that simulates seams of casing
1300. For example, in some cases, first indentation 1330 may include a plurality of
elongate portions arranged to demarcate a first central simulated panel portion 1333,
which may resemble a panel of casing 1300.
[0048] Second panel 1310 may include a fourth indentation 1335. Portions of fourth indentation
1335 may have an elongate configuration and may extend proximate to seam 1325. In
addition, fourth indention 1335 may define a second central simulated panel portion
1350. First central simulated panel portion 1333 and second central simulated panel
portion 1350 may have any suitable configurations. For example, as shown in Fig. 13,
the central simulated panel portions may have a polygonal shape, such as a pentagonal
shape, resembling a soccer ball panel.
[0049] In some embodiments, fourth indentation 1335 may be configured to correspond with
first indentation 1330 and second indentation 1325 across seam 1325. Accordingly,
first panel 1305 may also include a first mating panel portion 1340 defined by first
indentation 1330 and second indentation 1331. Second panel 1310 may include a second
mating panel portion 1345 defined by fourth indentation 1335. When first panel 1305
is joined to second panel 1310 at seam 1325, first mating panel portion 1340 may mate
with second mating panel portion 1345 to form a pattern across seam 1325. For example,
as shown in Fig. 13, first mating panel portion 1340 and second mating panel portion
1345 may combine to form a hexagonal casing portion that has the appearance of a hexagonal
casing panel. In some embodiments, seam 1325 may include an indentation. In other
embodiments, the exterior surface of casing 1300 may be substantially smooth across
seam 1325.
[0050] In some embodiments, one or more of the indentations may continue a pattern formed
by the plurality of seams joining panels of the casing. For example, as shown in Fig.
13, second indentation 1331 may be arranged in alignment with the edge of second panel
1310 and, therefore, may continue the pattern of a seam formed between second panel
1310 and an adjacent panel (not shown).
[0051] Fig. 14 shows portions of a casing 1400, including a first panel 1405 and a second
panel 1410, which may be joined to first panel 1405 at a seam 1425. First panel may
include a first exterior surface 1415 and second panel 1410 may include a second exterior
surface 1420. First panel 1405 and second panel 1410 may include
indentations in first exterior surface 1415 and second exterior surface 1420, in which
the indentations are arranged in the pattern shown in Fig. 7D. As shown in Fig. 14,
first panel 1405 may include a first indentation 1430, and second panel 1410 may include
a second indentation 1435. The indentations of first panel 1405 and second panel 1410
may have any of the configurations described above with respect to other disclosed
embodiments.
[0052] In some embodiments, first indentation 1430 and second indentation 1435 may be arranged
to form a pattern extending across seam 1425. For example, as shown in Fig. 14, in
some embodiments, first indentation 1430 and second indentation 1435 may each have
an elongate configuration. As further shown in Fig. 14, first indentation 1430 and
second indentation 1435 may be in substantial alignment with one another across seam
1425.
[0053] While various embodiments of the invention have been described, the description is
intended to be exemplary, rather than limiting and it will be apparent to those of
ordinary skill in the art that many more embodiments and implementations are possible
that are within the scope of the invention. Although many possible
combinations of features are shown in the accompanying figures and discussed in this
detailed description, many other combinations of the disclosed features are possible.
Therefore, it will be understood that any of the features shown and/or discussed in
the present disclosure may be implemented together in any suitable combination.
Accordingly, the invention is not to be restricted except in light of the attached
claims and their equivalents. Also, various modifications and changes may be made
within the scope of the attached claims.
Items
[0054]
Item 1: A sport ball comprising:
a casing that includes a plurality of panels joined at a plurality of seams, at least
a first panel of the plurality of panels having (a) a first layer including a polymer
material and positioned to form a portion of an exterior surface of the ball, (b)
a second layer including a polymer foam material and positioned inward and adjacent
to the first layer, and (c) a third layer positioned inward and adjacent to the second
layer, the first panel of the casing defining one or more indentations in the exterior
surface, the first layer being bonded directly to the third layer at the one or more
indentations, wherein the one or more indentations include a first indentation; and
a bladder located within the casing;
wherein the first indentation extends through substantially all of a thickness of
the first panel; and
wherein the first indentation has a substantially squared cross-sectional configuration.
Item 2: The sport ball recited in item 1, wherein the first indentation is spaced
from seams.
Item 3: The sport ball recited in item 1, wherein the first panel has one or more
peripheral edges joined to edges of adjacent panels of the casing to form one or more
seams, the first indentation extending to at least one of the one or more peripheral
edges.
Item 4: The sport ball recited in item 1, wherein the plurality of panels includes
a second panel joined to the first panel at a first seam of the one or more seams,
the second panel having (a) a fourth layer including a polymer material and positioned
to form a portion of an exterior surface of the ball, (b) a fifth layer including
a polymer foam material and positioned inward and adjacent to the fourth, and (c)
a sixth layer positioned inward and adjacent to the fifth layer, the second panel
of the casing defining a second indentation in the exterior surface, the fourth layer
being bonded directly to the sixth layer at the second indentation.
Item 5: The sport ball recited in item 4, wherein the first indentation has an elongate
configuration and extends proximate to a first seam; and
wherein the second indentation has an elongate configuration and extends proximate
to the first seam in substantial alignment with the first indentation.
Item 6: The sport ball recited in item 4, wherein the first indentation has an elongate
configuration and extends proximate to a first seam;
wherein the second indentation has an elongate configuration and extends proximate
to the first seam; and
wherein the first indentation and the second indentation are arranged to form a pattern
extending across the first seam.
Item 7: The sport ball recited in item 6, wherein the pattern includes one or more
portions of a polygon.
Item 8: The sport ball recited in item 1, wherein the one or more indentations continue
a pattern formed by the plurality of seams.
Item 9: A sport ball comprising:
a casing that includes a plurality of panels joined at a plurality of seams, at least
a first panel of the plurality of panels having (a) a first layer including a polymer
material and positioned to form a portion of an exterior surface of the ball, (b)
a second layer including a polymer foam material and positioned inward and adjacent
to the first layer, and (c) a third layer positioned inward and adjacent to the second
layer, the first panel of the casing defining one or more indentations in the exterior
surface, the first layer being bonded directly to the third layer at the one or more
indentations, wherein the one or more indentations include a first indentation; and
a bladder located within the casing;
wherein the first indentation is spaced from the seams;
wherein the first indentation extends through substantially all of a thickness of
the first panel; and
wherein the third layer includes an interior surface facing toward the interior of
the ball, the interior surface having a substantially planar configuration opposite
the first indentation in the exterior surface of the first panel.
Item 10: The sport ball recited in item 9, wherein the first indentation has a substantially
squared cross-sectional configuration.
Item 11: The sport ball recited in item 9, wherein the first panel has one or more
peripheral edges joined to edges of adjacent panels of the casing to form one or more
seams, the first indentation extending to at least one of the one or more peripheral
edges.
Item 12: The sport ball recited in item 9, wherein the first panel has one or more
peripheral edges joined to edges of adjacent panels of the casing to form one or more
seams, the first indentation extending to at least one of the one or more peripheral
edges.
Item 13: The sport ball recited in item 9, wherein the plurality of panels includes
a second panel joined to the first panel at a first seam of the one or more seams,
the second panel having (a) a fourth layer including a polymer material and positioned
to form a portion of an exterior surface of the ball, (b) a fifth layer including
a polymer foam material and positioned inward and adjacent to the fourth, and (c)
a sixth layer positioned inward and adjacent to the fifth layer, the second panel
of the casing defining a second indentation in the exterior surface, the fourth layer
being bonded directly to the sixth layer at the second indentation.
Item 14: The sport ball recited in item 13, wherein the first indentation has an elongate
configuration and extends proximate to a first seam; and
wherein the second indentation has an elongate configuration and extends proximate
to the first seam in substantial alignment with the first indentation.
Item 15: The sport ball recited in item 13, wherein the first indentation has an elongate
configuration and extends proximate to a first seam;
wherein the second indentation has an elongate configuration and extends proximate
to the first seam; and
wherein the first indentation and the second indentation are arranged to form a pattern
extending across the first seam.
Item 16: The sport ball recited in item 15, wherein the pattern includes one or more
portions of a polygon.
Item 17: The sport ball recited in item 9, wherein the one or more indentations continue
a pattern formed by the plurality of seams.
Item 18: A sport ball comprising:
a casing formed of a plurality of panels joined together at a plurality of seams,
the plurality of panels including a first panel and a second panel joined to the first
panel at a seam; and
a bladder located within the casing;
the first panel including (a) a first outer layer that defines a first indentation
in a first exterior surface of the first panel, (b) a first inner layer that defines
a first interior surface of the first panel, and (c) a first central layer, a majority
of the first outer layer of the first panel being spaced from the first inner layer
of the first panel by the first central layer, and the first outer layer of the first
panel being directly bonded to the first inner layer of the first panel at the first
indentation; and
the second panel including (a) a second outer layer that defines a second indentation
in a second exterior surface of the second panel, (b) a second inner layer that defines
a second interior surface of the second panel, and (c) a second central layer, a majority
of the second outer layer of the second panel being spaced from the second inner layer
of the second panel by the second central layer, and the second outer layer of the
second panel being directly bonded to the second inner layer of the second panel at
the second indentation;
wherein the first indentation extends proximate to the seam and the second indentation
extends proximate to the seam; and
wherein the first indentation is configured to correspond with the second indentation
across the seam.
Item 19: The sport ball recited in item 18, wherein the first indentation has an elongate
configuration and the second indentation has an elongate configuration; and
wherein the second indentation extends in substantial alignment with the first indentation.
Item 20: The sport ball recited in item 18, wherein the first indentation has an elongate
configuration and the second indentation has an elongate configuration; and
wherein the first indentation and the second indentation are arranged to form a pattern
extending across the seam.
Item 21: The sport ball recited in item 20, wherein the pattern includes one or more
portions of a polygon.
Item 22: The sport ball recited in item 18, wherein the one or more indentations continue
a pattern formed by the plurality of seams.
Item 23: The sport ball recited in item 18, wherein the first indentation has a substantially
squared cross-sectional configuration.
1. A sport ball (10) comprising:
a casing (1300; 71) formed from a plurality of panels (21) joined together at a plurality
of seams (1325);
wherein each of the plurality of panels (21) has:
(a) a first layer (51; 71) formed from a polymer material and positioned to form a
portion of an exterior surface of the sport ball (10);
(b) a second layer (52; 72) formed from a polymer foam material and positioned inward
and adjacent to the first layer (51;71);
(c) a third layer (53; 73) positioned inward and adjacent to the second layer (52;
72); and
a thickness;
wherein the first layer (51; 71) of at least one of the plurality of panels (21) defines
a first indentation (1330, 1430) therein;
wherein the first layer (51; 71) is bonded directly to the third layer (53; 73) at
the first indentation (1330, 1430);
wherein the first indentation (1330, 1430) extends through an entirety of the thickness;
and
a bladder (40; 73) located within the casing (1300; 71).
(29) (29)
2. The sport ball (10) of claim 1, wherein the first indentation (1330, 1430) has a first
shoulder (29) and a second shoulder (29) each having a substantially squared cross-sectional
configuration.
3. The sport ball (10) of claim 1, wherein the third layer (53; 73) has an interior surface
(24) facing toward an interior of the sport ball (10) and the interior surface (24)
has a substantially planar configuration opposite the first indentation (1330, 1430)
in exterior surface (23) of panel (21).
4. A sport ball (10) comprising:
a casing (1300; 71) formed from a plurality of panels (21) joined together at a plurality
of seams (1325);
wherein each of the plurality of panels (21) has:
(a) a first layer (51; 71) formed from a polymer material and positioned to form a
portion of an exterior surface of the sport ball (10);
(b) a second layer (52; 72) formed from a polymer foam material and positioned inward
and adjacent to the first layer (51; 71);
(c) a third layer (53; 73) positioned inward and adjacent to the second layer (52;
72); and
a thickness;
wherein the first layer (51; 71) of at least one of the plurality of panels (21) defines
a first indentation (1330, 1430) therein;
wherein the third layer (53; 73) of the at least one of the plurality of panels (21)
defines a second indentation (1331, 1435) therein;
wherein the first indentation (1330, 1430) and the second indentation (1331, 1435)
each have a generally rounded configuration that extends to an approximate midpoint
of each of the plurality of panels (21) (21); and
a bladder (40; 73) located within the casing (1300; 71).
5. The sport ball (10) of claim 4, wherein the first indentation (1330, 1430) has a first
shoulder (29) and a second shoulder (29) each having a substantially square configuration.
6. The sport ball (10) of claim 5, wherein the second indentation (1331, 1435) has a
third shoulder (29) and a fourth shoulder (29) each having a substantially squared
cross-sectional configuration.
7. A sport ball (10) comprising:
a casing (1300; 71) formed from a plurality of panels (21) joined together at a plurality
of seams (1325);
wherein a first panel (21) of the plurality of panels (21) has:
(a) a first layer (51; 71) formed from a polymer material and positioned to form a
portion of an exterior surface of the sport ball (10);
(b) a second layer (52; 72) formed from a polymer foam material and positioned inward
and adjacent to the first layer (51; 71);
(c) a third layer (53; 73) positioned inward and adjacent to the second layer (52;
72); and
a first thickness;
wherein the first layer (51; 71) defines a first indentation (1330, 1430) therein,
a second indentation (1331, 1435) therein spaced apart from the first indentation
(1330, 1430), and a third indentation (1332) therein spaced apart from the first indentation
(1330, 1430) and the second indentation (1331, 1435);
wherein the first layer (51; 71) is bonded directly to the third layer (53; 73) at
the first indentation (1330, 1430), the second indentation (1331, 1435), and the third
indentation (1332);
wherein at least one of the first indentation (1330, 1430), the second indentation
(1331, 1435), and the third indentation (1332) includes a first plurality of elongated
portions arranged to demarcate a first simulated panel (21) portion;
wherein a second panel (21) of the plurality of panels (21) has:
(a) a fourth layer formed from a polymer material and positioned to form a portion
of the exterior surface of the sport ball (10);
(b) a fifth layer formed from a polymer foam material and positioned inward and adjacent
to the fourth layer;
(c) a sixth layer positioned inward and adjacent to the fifth layer; and
a second thickness;
wherein the fourth layer defines a fourth indentation (1335) therein, a fifth indentation
therein spaced apart from the fourth indentation (1335), and a sixth indentation therein
spaced apart from the fourth indentation (1335) and the fifth indentation;
wherein the fourth layer is bonded directly to the sixth layer at the fourth indentation
(1335), the fifth indentation, and the sixth indentation;
wherein at least one of the fourth indentation (1335), the fifth indentation, and
the sixth indentation includes a second plurality of elongated portions arranged to
demarcate a second simulated panel (21) portion;
wherein the fourth indentation (1335) is configured to correspond with the first indentation
(1330, 1430) across one of the plurality of seams (1325) to form a pattern across
the one of the plurality of seams (1325); and
a bladder (40; 73) located within the casing (1300; 71).
8. The sport ball (10) of claim 7, wherein the first simulated panel (21) portion and
the second simulated panel (21) portion each have a polygonal shape.
9. The sport ball (10) of claim 8, wherein the first simulated panel (21) portion and
the second simulated panel (21) portion each have a pentagonal shape.
10. The sport ball (10) of claim 8, wherein the first simulated panel (21) portion and
the second simulated panel (21) portion each have a hexagonal shape.
11. The sport ball (10) of claim 7, wherein the first indentation (1330, 1430), the second
indentation (1331, 1435), and the third indentation (1332) extend to an approximate
midpoint of the first thickness.
12. The sport ball (10) of claim 7, wherein the fourth indentation (1335), the fifth indentation,
and the sixth indentation extend to an approximate midpoint of the second thickness.
13. The sport ball (10) of claim 7, wherein the first indentation (1330, 1430), the second
indentation (1331, 1435), and the third indentation (1332) extend through an entirety
of the first thickness.
14. The sport ball (10) of claim 7, wherein the first indentation (1330, 1430) has a first
shoulder (29) and a second shoulder (29) each having a substantially squared cross-sectional
configuration.