Abstract: A method of forming a cushioning element. The method including placing a first sheet adjacent to an outer surface of a first mold portion, the first mold portion including a first mold cavity. The method including pressing a portion of the first sheet into the first mold portion and into the first mold cavity with a forming tool, wherein at least a portion of the forming tool is extended into the first mold cavity. The method including applying negative pressure to the first mold cavity to draw the portion of the first sheet into the first mold cavity, and joining a second sheet to the first sheet to form the cushioning element.

Abstract: A sport ball includes a casing that includes a plurality of joined panels and defines a cavity. The casing includes at least a first panel having (a) a first layer positioned to form a portion of an exterior surface of the sport ball, (b) a second layer disposed adjacent to the first layer, and (c) a third layer disposed adjacent to the second layer. The first panel defines a first indentation and a second indentation spaced apart from the first indentation. The first indentation has a first depth and the second indentation has a second depth that is less than the first depth. The first depth is from 0.5 times to 4 times larger than the second depth. The sport ball also includes a bladder disposed within the cavity.

Abstract: A sport ball includes a casing that includes a plurality of joined panels and defines a cavity. The casing includes at least a first panel having (a) a first layer positioned to form a portion of an exterior surface of the sport ball, (b) a second layer disposed adjacent to the first layer, and (c) a third layer disposed adjacent to the second layer. The first panel defines a first indentation and a second indentation spaced apart from the first indentation. The first indentation has a first depth and the second indentation has a second depth that is less than the first depth. The first depth is from 0.5 times to 4 times larger than the second depth. The sport ball also includes a bladder disposed within the cavity.

Abstract: A sport ball includes a casing formed from a plurality of panels joined together at a plurality of seams. Each of the plurality of panels includes (a) a first layer having a first thickness, formed from a polymer material, and positioned to form a portion of an exterior surface of the sport ball; (b) a second layer having a second thickness, formed from 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 layer defines a first indentation therein. The first layer is bonded directly to the third layer at the first indentation, and the first indentation has a first indentation thickness equal to a sum of the first thickness and the second thickness. The sport ball also includes a bladder located within the casing.

Abstract: A sport ball includes a casing that includes a plurality of joined panels and defines a cavity. The casing includes at least a first panel having (a) a first layer positioned to form a portion of an exterior surface of the sport ball, (b) a second layer disposed adjacent to the first layer, and (c) a third layer disposed adjacent to the second layer. The first panel defines a first indentation and a second indentation spaced apart from the first indentation. The first indentation has a first depth and the second indentation has a second depth that is less than the first depth. The sport ball also includes a bladder disposed within the cavity.

Abstract: A method of making a spherical sport ball includes forming a casing having a first and a second substantially hemispherical panel component. The first panel component is a first unitary structure and has a first central panel, a first plurality of polygonal peripheral panels adjacent to the first central panel and having a first plurality of edges, and a plurality of flange areas extending from the first plurality of edges. The second panel component is a second unitary structure and has a second central panel and a second plurality of polygonal peripheral panels adjacent to the second central panel. The method includes joining together the first panel component and the second panel component at a non-linear, circumferential seam between the first and second plurality of polygonal peripheral panels. The method also includes forming a vertex between adjacent ones of the plurality of flange areas.

Abstract: A sport ball includes a casing that includes a plurality of joined panels and defines a cavity. The casing includes at least a first panel having (a) a first layer positioned to form a portion of an exterior surface of the sport ball, (b) a second layer disposed adjacent to the first layer, and (c) a third layer disposed adjacent to the second layer. The first panel defines a first indentation and a second indentation spaced apart from the first indentation. The first indentation has a first depth and the second indentation has a second depth that is less than the first depth. The sport ball also includes a bladder disposed within the cavity.

Abstract: A sport ball includes a casing formed from a plurality of panels joined together at a plurality of seams. Each of the plurality of panels includes (a) a first layer having a first thickness, formed from a polymer material, and positioned to form a portion of an exterior surface of the sport ball; (b) a second layer having a second thickness, formed from 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 layer defines a first indentation therein. The first layer is bonded directly to the third layer at the first indentation, and the first indentation has a first indentation thickness equal to a sum of the first thickness and the second thickness. The sport ball also includes a bladder located within the casing.

Abstract: A sport ball may include a casing that forms an exterior surface of the sport ball. The casing may incorporate a plurality of joined panels, including a closure panel. In addition, the ball may include a backing layer located radially inward of the closure panel, the backing layer extending beyond a peripheral boundary of the closure panel and at least partially overlapping with one or more panels adjacent to the closure panel. The backing layer may also include an opening located radially inward of the closure panel, the opening being smaller than the surface area of the closure panel. Also, the ball may include a bladder located radially inward of the backing layer, the bladder including a valve for introducing fluid into the ball, the valve extending through the opening and through the closure panel.

Abstract: A sport ball includes a casing formed from a plurality of panels joined together at a plurality of seams. Each of the plurality of panels has (a) a first layer formed from a polymer material and positioned to form a portion of an exterior surface of the sport ball; (b) a second layer formed from a polymer foam material and positioned inward and adjacent to the first layer; (c) a third layer positioned inward and adjacent to the second layer; and a thickness. The first layer of at least one of the plurality of panels defines a first indentation therein. The first layer is bonded directly to the third at the first indentation, and the first indentation extends through an entirety of the thickness. The sport ball also includes a bladder located within the casing.

Abstract: A sport ball may include a casing and a bladder located within the casing. The casing may include a plurality of panel elements joined to each other with welds, and portions of the panel elements that include the welds may project toward an interior of the ball. A method of manufacturing a sport ball may include providing a plurality of casing elements that include a thermoplastic polymer material. Edges of the casing elements are welded to each other to join the casing elements. The casing elements may then be turned inside-out through an aperture formed by at least one of the casing elements, and the aperture may be sealed.

Abstract: A sport ball may include a casing that incorporates a plurality of joined panel elements, which include a first panel element with a first edge and a second panel element with a second edge. The first edge and the second edge are welded to each other. In some configurations, the first panel element has a first edge with a projection that extends outward from the first edge, the second panel element has a second edge that is located adjacent to the first edge, and the projection of the first edge is located between the second edge and the bladder. In another configuration, the first edge and the second edge are formed to have rounded configurations. The sport ball may also include an intermediate layer and a bladder within the casing.

Abstract: A sport ball includes a casing forming an exterior surface thereof. The casing has a plurality of joined panels forming a partially-assembled casing and defining an open area. A closure panel substantially fills the open area of the partially-assembled casing. A backing layer is radially inward of, and attached to, the closure panel. The backing layer extends beyond a peripheral boundary of the closure panel, such that the backing layer at least partially overlaps one or more of the joined panels adjacent to the open area of the partially-assembled casing. A bladder is radially inward of, and attached to, the closure panel. The bladder includes a valve for introducing fluid into the ball. The valve extends through the backing layer and the closure panel. A backing patch may be attached either to the closure or the partially-assembled casing, and overlaps a portion of both.

Abstract: A method of making a spherical sport ball includes forming a casing having a first and a second substantially hemispherical panel component. The first panel component is a first unitary structure and has a first central panel, a first plurality of polygonal peripheral panels adjacent to the first central panel and having a first plurality of edges, and a plurality of flange areas extending from the first plurality of edges. The second panel component is a second unitary structure and has a second central panel and a second plurality of polygonal peripheral panels adjacent to the second central panel. The method includes joining together the first panel component and the second panel component at a non-linear, circumferential seam between the first and second plurality of polygonal peripheral panels. The method also includes forming a vertex between adjacent ones of the plurality of flange areas.

Abstract: A spherical sport ball may include a casing that includes first and second substantially hemispherical panel components. Each substantially hemispherical panel component may be a unitary structure having a central panel and a plurality of polygonal peripheral panels adjacent to the central panel. In addition, the first substantially hemispherical panel component may be joined with the second substantially hemispherical panel component at a non-linear, circumferential seam between peripheral panels of the first hemispherical panel component and peripheral panels of the second hemispherical panel component.

Abstract: An apparatus for manufacturing a sport ball may include a first component having a first baseplate and a plurality of support structures extending from the first baseplate and a second component having a second baseplate and a plurality of welding dies extending from the second baseplate. The apparatus may be configured such that, when the first component is assembled with the second component, each of the plurality of welding dies extending from the second baseplate of the second component aligns with one of the support structures extending from the first baseplate of the first component. In addition, the apparatus may be further configured to compress edges of casing panels against one another between the welding dies and the support structures. Further, the second component may be configured to supply welding energy to edges of casing panels when the casing panels are compressed between the welding dies and the support structures.

Abstract: A sport ball may incorporate a casing that includes a plurality of joined panels. At least one of the panels may have a first layer, a second layer, and a third layer. The casing defines at least one indentation in the exterior surface, and the first layer is bonded to the third layer adjacent to the indentation. In some configurations, the casing may also define at least one indentations in a surface of the third layer, which may correspond in location with the indentation in the exterior surface. Additionally, the sport ball may include an intermediate structure and a bladder located within the casing.

Abstract: A sport ball includes a casing formed from a plurality of panels joined together at a plurality of seams. Each of the plurality of panels has (a) a first layer formed from a polymer material and positioned to form a portion of an exterior surface of the sport ball; (b) a second layer formed from a polymer foam material and positioned inward and adjacent to the first layer; (c) a third layer positioned inward and adjacent to the second layer; and a thickness. The first layer of at least one of the plurality of panels defines a first indentation therein. The first layer is bonded directly to the third at the first indentation, and the first indentation extends through an entirety of the thickness. The sport ball also includes a bladder located within the casing.

Abstract: A sport ball may include a casing and a bladder. The casing includes a plurality of panels having edge areas joined to each other with bonds, and the edge areas project toward an exterior of the ball. The bladder is located within the casing. In another aspect, the casing includes a first panel and a second panel that each have an exterior surface facing outward and an opposite interior surface facing inward. The interior surface of the first panel is bonded to the interior surface of the second panel to form a seam that joins the first panel and the second panel together. A method of manufacturing the casing may include forming thermal bonds between the panels.

Abstract: A sport ball may include a plurality of panels having a first surface and an opposite second surface, the first surface forming a majority of an exterior surface of the ball. In addition, the sport ball may include an interior layer secured to the second surface of the panels and forming substantially all of an interior surface of the ball to retain a fluid within the ball, the interior layer extending between the panels to join the panels together. Further the sport ball may include a valve secured to the interior layer.