Sports Ball with Integral Ball Casing and Bladder Body

Abstract

A sports ball includes a barebone ball and an outer ball layer. The barebone ball includes an inflatable bladder body and a ball casing. The ball casing, which is formed in an integrated structure, has an outer circumferential surface, an inner circumferential surface to define an interior cavity to fittingly enclose the bladder body therein, and a plurality of pre-formed channels integrally and indently formed on the outer circumferential surface, such that the ball casing and the bladder body enclosed therewithin form a one piece integrated semi-product of the sports ball. The outer ball layer comprising a plurality of outer cover panels overlapping on the outer circumferential surface of the ball casing at a position that edges of each of the outer cover panels are aligned with the corresponding pre-formed channels respectively.

Description

CROSS REFERENCE OF RELATED APPLICATION

This is a divisional application that claims the benefit of priority under 35 U.S.C. §119 to a non-provisional application, application Ser. No. 12/070,557, filed Feb. 19, 2008.

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention

The present invention relates to a ball, and more particularly to a sports ball comprising a barebone ball having an integral structure for optimizing a structural strength of the sports ball.

2. Description of Related Arts

A conventional sports ball, such as a conventional soccer ball, usually comprises a ball bladder, an inner lining, and a ball carcass. The ball carcass comprises a plurality of carcass panels attached on the ball bladder, wherein each of the carcass panels is usually stitched to adjacent carcass panels for forming a substantially round sports ball. Traditionally, much has been done in the development of the ball bladder and intermediate construction between the ball bladder and the ball carcass.

However, there are also several disadvantages for this kind of traditional sports ball. For example, the carcass panels, being attached onto the ball bladder, involve expensive and time-consuming manufacturing procedures, yet the resulting sports ball may not have the optimal roundness. One particularly-pressing problem for conventional stitched sports ball is that the carcass panels cannot have too sharp a shape for it is difficult for sharp corners to be adequately stitched with adjacent carcass panels.

As a result, sports balls having a stitch-less structure have been developed to overcome the many conventional deep-seated problems present in stitched sports ball. For example, U.S. Pat. No. 6,685,585 to Hiroshima et al. discloses a ball for a ball game comprising an elastic bladder, a reinforced layer, and a plurality of leather panels. More specifically, each of the leather panels is bonded onto the reinforced layer, wherein a peripheral edge portion of each leather panels is folded toward an inside. A thickness adjusting member is disposed in a void defined by the folded peripheral portions and bonded onto a back of each leather panel. Although this sports ball does not involve stitching on the leather panels, thereby substantially overcoming the disadvantages associated with stitching, it has several other disadvantages.

First, the Hiroshima's patent specifically discloses a bonding technique thereby each of the leather panels is inwardly folded at the corresponding peripheral portion to bond with the thickness adjusting member. Thus, the Hiroshima's patent discloses a state of art where each the leather panels has two portions, a main portion which is above the thickness adjusting member, and a peripheral portion which is bonded at side portions of the corresponding thickness adjusting member. Now, the problem with this construction is that while the main portion of each of the leather panels is elastically supported by the thickness adjusting member, the corresponding peripheral portion does not. As a result, the sports ball suffers from non-uniform cushion effect because of the bonding technique of the leather panels. When a user of that invention kicks on the main portion of the leather panel, he will enjoy substantial cushioning effect from the thickness adjusting member. However, when the user kicks on the peripheral portion of the leather panel, he will cease to enjoy the same amount of cushioning effect as if he kicks on the main portion.

Second, it is reasonably clear that in order to manufacture the ball stated in the Hiroshima's patent, one must take substantial amount of time for precise and effective attachment between the thickness adjusting member and the leather panels. In other words, the ball disclosed in the Hiroshima's patent requires expensive manufacturing cost. Moreover, since the manufacturing procedures are time-consuming, when the balls are needed in large quantity, such as when the inventors or their assignees or the licensors need to meet substantial market demand, there is little chance that they could produce the balls in large quantity in a relatively short period of time. This is extremely important because major soccer events, such as World Cup, are only held once in a few years.

Another problem for traditional sports balls is that no matter how good the stitching and/or the construction of leather panels, the ball bladder and the ball carcass are inherently two different components. The ball carcass may be attached onto the ball bladder with an inner lining in between, the attachment may not be good enough so that the sports ball may have a reduced span of life.

SUMMARY OF THE PRESENT INVENTION

A main object of the present invention is to provide a sports ball comprising a barebone ball having an integral structure for optimizing a structural strength of the sports ball.

Another object of the present invention is to provide a sports ball comprising an inflatable bladder body, and a ball casing integrally formed with the inflatable bladder body so as to completely overcome the insecure attachment disadvantage for conventional sports ball.

Another object of the present invention is to provide a sports ball comprising a barebone ball, wherein the sports ball can be manufactured into a wide variety of ball types, so as to facilitate widespread applications of the present invention. For example, the sports ball can be manufactured as a soccer ball, an America football, or even a volley ball with even cushioning throughout the entire sports ball.

Another object of the present invention is to provide a method of manufacturing a sports ball comprising a barebone ball having an integral structure for optimizing a structural strength of the sports ball.

Another object of the present invention is to provide a method of manufacturing a sports ball, wherein the method reduces the number of steps for manufacturing a traditional sports ball so as to minimize the manufacturing cost of a sports ball.

Accordingly, in order to accomplish the above objects, the present invention provides a sports ball, comprising:

• • a barebone ball, which comprises
  • an inflatable bladder body; and
  • a ball casing, which is formed in an integrated structure, having an outer circumferential surface, an inner circumferential surface to define an interior cavity to fittingly enclose the bladder body therein, and a plurality of pre-formed channels integrally and indently formed on the outer circumferential surface, such that the ball casing and the bladder body enclosed therewithin form a one piece integrated semi-product of the sports ball; and
  • an outer ball layer comprising a plurality of outer cover panels overlappedly attached on the outer circumferential surface of the ball casing at a position that edges of each of the outer cover panels are aligned with the corresponding pre-formed channels respectively.

Moreover, the present invention also provides a method of manufacturing a sports ball, comprising the steps of:

• • (a) providing an inflatable bladder body and a ball casing having a shape corresponding to the bladder body after being inflated;
  • (b) placing the bladder body and the ball casing in a casing mold at a position that the bladder body is enclosed within the ball casing;
  • (c) vulcanizing the ball casing with heat to integrally bond the ball bladder with the ball casing to form a one piece integrated barebone ball as a semi-product of the sports ball, wherein a plurality of pre-formed channels are integrally and indently formed on an outer circumferential surface of the ball casing; and
  • (d) overlappedly attaching a plurality of outer cover panels on the outer circumferential surface of the ball casing at a position that edges of each of the outer cover panels are aligned with the corresponding pre-formed channels respectively to form an outer ball layer to enclose the ball casing.

These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A to FIG. 1D is schematic diagrams of a method of manufacturing a sports ball according to a preferred embodiment of the present invention.

FIG. 2 is a perspective view of a sports ball according to a preferred embodiment of the present invention.

FIG. 3 is a perspective view of the inflatable bladder body of the sports ball according to the above preferred embodiment of the present invention.

FIG. 4 is a sectional side view of the sports ball according to the above preferred embodiment of the present invention.

FIG. 5 is a perspective view of an alternative mode of the sports ball according to the above preferred embodiment of the present invention.

FIG. 6 is a perspective view of the alternative mode of the inflatable bladder body of the sports ball according to the above preferred embodiment of the present invention.

FIG. 7 is a sectional side view of the alternative mode of the sports ball according to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1A, FIG. 1C, FIG. 1D, and FIG. 2 to FIG. 4 of the drawings, a method of manufacturing a sports ball according to the preferred embodiment of the present invention is illustrated, in which the method comprises the steps of:

• • (a) providing an inflatable bladder body 11 and a ball casing 12 having a shape corresponding to the bladder body 11 after being inflated;
  • (b) placing the bladder body 11 and the ball casing 12 in a casing mold 70 at a position that the bladder body 11 is enclosed within the ball casing 12;
  • (c) vulcanizing the ball casing 12 with heat to integrally bond the bladder body 11 with the ball casing 12 to form a one piece integrated barebone ball 10 as a semi-product of the sports ball, wherein a plurality of pre-formed channels 124 are integrally and indently formed on an outer circumferential surface 121 of the ball casing 12; and
  • (d) overlappedly attaching a plurality of outer cover panels 21 on the outer circumferential surface 121 of the ball casing 12 at a position that edges of each of the outer cover panels 21 are aligned with the corresponding pre-formed channels 124 respectively to form an outer ball layer to enclose the ball casing 12.

Step (b) further comprises a step of aligning two or more casing panels 126 edge-to-edge to form the ball casing 12 such that the casing panels 126 are aligned to enclose the bladder body 11 in the casing mold 70.

In step (c), the casing mold 70 comprises a plurality of channel protrusions 71 integrally protruded from an inner mold surface to press against the outer circumferential surface 121 of the ball casing 12 during vulcanization. Each of the channel protrusions 71 has two slanted pressing surfaces 711 such that each of the per-formed channels 124 is formed to have two slanted sidewalls 1241 indented on the outer circumferential surface 121 of the ball casing 12 during vulcanization, so that edge portions of the two neighboring outer cover panels 21 are overlappedly attached on the slanted sidewalls 1241 of the corresponding pre-formed channel 124 respectively so as to be securely and fittedly attached onto the barebone ball 10.

In step (d), the outer cover panels 21 are securely and fittedly adhered on the outer circumferential surface 121 of the ball casing 12 of the barebone ball 10.

According to the preferred embodiment of the present invention, the outer circumferential surface of the bladder body 11 is integrated with the inner circumferential surface 122 of the ball casing 12 to form the one piece integrated barebone ball 10 after vulcanization. The ball casing 12 is made of rubber material for providing a cushion effect at any point of the barebone ball 10 after vulcanization.

It is worth mentioning that the sports ball of the present invention can be manufactured as a soccer ball, a volley ball or even an America football. Preferably, the soccer ball is made by the above mentioned structure and its manufacturing process thereof.

Referring to FIG. 2 to FIG. 4 of the drawings, a sports ball according to a preferred embodiment of the present invention is illustrated, in which the sports ball comprises a barebone ball 10 and an outer ball layer 20. Accordingly, the sports ball of the present invention is illustrated as a soccer ball.

The barebone ball 10 comprises an inflatable bladder body 11 and a ball casing 12. The ball casing 12, which is formed in an one-piece integrated structure, has an outer circumferential surface 121, an inner circumferential surface 122 to define an interior cavity 123 to fittingly enclose the bladder body 11 therein, and a plurality of pre-formed channels 124 integrally and indently formed on the outer circumferential surface 121, such that the ball casing 12 and the bladder body 11 enclosed therewithin form a one piece integrated semi-product of the sports ball.

On the other hand, the outer ball layer 20 comprises a plurality of outer cover panels 21 overlappedly attaching on the outer circumferential surface 121 of the ball casing 12 at a position that edges of each of the outer cover panels 21 are aligned with the corresponding pre-formed channels 124 respectively so as to fittedly attach onto the ball casing 12.

According to the preferred embodiment of the present invention, each of the per-formed channels 124 has two slanted sidewalls 1241 indented on the outer circumferential surface 121 of the ball casing 12 such that edge portions of the two neighboring outer cover panels 21 are overlappedly attached on the sidewalls 1241 of the corresponding pre-formed channel 124 respectively such that each of the outer cover panels 21 are adapted to be fittedly attached onto the outer circumferential surface 121 along the corresponding pre-formed channels 124.

It is worth mentioning that an outer circumferential surface 114 of the bladder body 11 is integrated with the inner circumferential surface 122 of the ball casing 12 after the ball casing 12 is heat-treated to form the one piece integrated semi-product of the sports ball. As a result, the ball casing 12 and the bladder body 11 is integrated as a one-piece body so as to possess the optimal roundness of the ball casing 12 and the structural integrity and strength of the semi-product of the sports ball. Moreover, the ball casing 12 is made of rubber or other soft materials (such as PVC, foaming materials etc.) for providing a cushion effect at any point of the barebone ball 10. Since the ball casing 12 is formed as a one-piece semi-product without involving stitching or any other mechanical connection mechanisms, the ball casing 12 is capable of possessing a truly rounded outer shape with optimally even cushioning effect and maximal structural integrity and strength. In other words, the present invention resolves the problem of inadequate roundness and weak structural integrity of conventional sports ball. Moreover, the outer cover panels 21 are adhered on the outer circumferential surface 121 of the ball casing 12 of the barebone ball 10.

It is worth mentioning that the barebone ball 10 can also be considered as a final product of the sports ball without the outer ball layer 20, wherein the ball casing 12 of the barebone ball 10 can be considered as the carcass panels of the sports ball. Moreover, it is worth mentioning that the channels 124 pre-formed on the barebone ball 10 can also be used as a water repellent guiding channels when the sports ball of the present invention is played in a wet condition, such as in a raining day.

As shown in FIG. 3 of the drawings, the inflatable bladder body 11 comprises an inflatable bladder 111 for being popped by air inflation and an exterior web layer 112, which is integrally attached on an outer surface of the inflatable bladder 111, and comprises at least an elongated strengthened thread 113 evenly wound around the outer surface of the inflatable bladder 111 such that the web layer 112 embraces the inflatable bladder 111 for resisting stress and impact force applied to the inflatable bladder 111.

In other words, the inflatable bladder body 10, which is disposed inside the ball casing 12, comprises a rubber made inflatable bladder 111 and a valve stem 114 mounted thereon wherein the ball casing 12 has a valve hole 125 formed thereon for aligning with the valve stem 114. The inflatable bladder body 10 comprises an exterior web layer 112 integrally attached on an outer surface of the inflatable bladder 111.

In order to enable the strengthened threads 113 being permanently affixed on the outer surface of the inflatable bladder 111, before winding onto the inflatable bladder 111, the strengthened threads 113 are coated with glue for adhering onto the outer surface of the inflatable bladder 111 and each other. Moreover, the inflatable bladder 111 with the adhering strengthened threads 113 thereon are together cured by heating in a mold, so that the adhering strengthened threads 113 will be hardened to form the exterior web layer 112 which is permanently united with the inflatable bladder 111 integrally.

As an alternative mode shown in FIG. 1B, and FIG. 5 to FIG. 7 of the drawings, the barebone ball 10′ comprises an inflatable bladder body 11′ and a ball casing 12′. The ball casing 12′, which is formed in a one-piece integrated structure, has an outer circumferential surface 121′, an inner circumferential surface 122′ to define an interior cavity 123′ to fittingly enclose the bladder body 11′ therein, and a plurality of pre-formed channels 124′ integrally and indently formed on the outer circumferential surface 121′, such that the ball casing 12′ and the bladder body 11′ enclosed therewithin form a one piece integrated semi-product of the sports ball.

On the other hand, the outer ball layer 20′ comprises a plurality of outer cover panels 21′ overlappedly attaching on the outer circumferential surface 121′ of the ball casing 12′ at a position that edges of each of the outer cover panels 21′ are aligned with the corresponding pre-formed channels 124′ respectively so as to fittedly attach onto the ball casing 12′.

Moreover, the bladder body 11′ comprises an inflatable bladder 111′ for being popped by air inflation and a construction ball pocket 112′, which is made of fabric material and constructed to have a true roundness shape, having an interior receiving cavity defined therein to sealedly receive the inflatable bladder 111′, such that the construction ball pocket 112′ is arranged to retain a true roundness shape of the inflatable bladder 111′ after the inflatable bladder 111′ is inflated. According to the preferred embodiment, the inflatable bladder 111′ is made of rubber or the like that is capable of being inflated with a compression air at a predetermined pressure for popping up and supporting the ball casing 12′.

The construction ball pocket 112′ comprises a plurality of ball pocket leaves 1121′ integrally connected with each other. Practically, the fabric made construction ball pocket 112′ is able to form a spherical body that the construction ball pocket 112′ is constructed to have a true roundness shape so as to retain a maximum diameter of the inflatable bladder 111′ after it is inflated.

The construction ball pocket 112′ is preferred to be made of fabric material having a durability, stretchability and adhesiveablility. Preferably, the construction ball pocket 112′ can be made of a mixture fabric mixed with cotton and polyester because the cotton has a good stretchability and is able to absorb adhesive material and the polyester is durable and has a strong strength that is able to resist strain when the inflatable bladder 111′ is inflated.

The inflatable bladder 111′ is disposed in the construction ball pocket 112′ which has a size slightly bigger than the inflatable bladder 111′ in such a manner that when the inflatable bladder 111′ is inflated, an outer spherical surface of the inflatable bladder 111′ is preferred to be slightly spaced apart from an inner spherical surface of the construction ball pocket 112′ to form an air cushion layer therebetween. The air cushion layer is adapted for providing a cushion effect for the sports ball to provide softness for the sports ball and tolerate heavier impact thereon.

It is worth mentioning that the barebone ball 10 may further an inner lining layer integrally formed between the ball casing 12 and the inflatable bladder body 11 for further reinforcing a strength of the barebone ball 10.

One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.

It will thus be seen that the objects of the present invention have been fully and effectively accomplished. The embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.

Claims

1. A method of manufacturing a sports ball, comprising the steps of:

(a) providing an inflatable bladder body and a ball casing having a shape corresponding to said bladder body after being inflated;

(b) placing said bladder body and said ball casing in a casing mold at a position that said bladder body is enclosed within said ball casing;

(c) vulcanizing said ball casing with heat to integrally bond said ball bladder with said ball casing to form a one piece integrated barebone ball as a semi-product of said sports ball, wherein a plurality of pre-formed channels are integrally and indently formed on an outer circumferential surface of said ball casing; and

(d) overlappedly attaching a plurality of outer cover panels on said outer circumferential surface of said ball casing at a position that edges of each of said outer cover panels are aligned with said corresponding pre-formed channels respectively to form an outer ball layer to enclose said ball casing.

2. The method, as recited in claim 1, wherein the step (b) further comprises a step of aligning two or more casing panels edge-to-edge to form said ball casing such that said casing panels are aligned to enclose said bladder body in said casing mold.

3. The method as recited in claim 1, wherein, in the step (c), said casing mold comprises a plurality of channel protrusions integrally protruded from an inner mold surface to press against said outer circumferential surface of said ball casing during vulcanization.

4. The method as recited in claim 2, wherein, in the step (c), said casing mold comprises a plurality of channel protrusions integrally protruded from an inner mold surface to press against said outer circumferential surface of said ball casing during vulcanization.

5. The method, as recited in claim 3, wherein each of said channel protrusions has two slanted pressing surfaces that each of said per-formed channels is formed to have two slanted sidewalls indented on said outer circumferential surface of said ball casing during vulcanization, so that edge portions of said two neighboring outer cover panels are overlappedly attached on said sidewalls of said corresponding pre-formed channel respectively.

6. The method, as recited in claim 4, wherein each of said channel protrusions has two slanted pressing surfaces that each of said per-formed channels is formed to have two slanted sidewalls indented on said outer circumferential surface of said ball casing during vulcanization, so that edge portions of said two neighboring outer cover panels are overlappedly attached on said sidewalls of said corresponding pre-formed channel respectively.

7. The method, as recited in claim 1, wherein an outer circumferential surface of said bladder body is integrated with said inner circumferential surface of said ball casing to form said one piece integrated barebone ball after vulcanization.

8. The method, as recited in claim 2, wherein an outer circumferential surface of said bladder body is integrated with said inner circumferential surface of said ball casing to form said one piece integrated barebone ball after vulcanization.

9. The method, as recited in claim 5, wherein an outer circumferential surface of said bladder body is integrated with said inner circumferential surface of said ball casing to form said one piece integrated barebone ball after vulcanization.

10. The method, as recited in claim 6, wherein an outer circumferential surface of said bladder body is integrated with said inner circumferential surface of said ball casing to form said one piece integrated barebone ball after vulcanization.

11. The method, as recited in claim 1, wherein said ball casing is made of rubber material for providing a cushion effect at any point of said barebone ball after vulcanization.

12. The method, as recited in claim 2, wherein said ball casing is made of rubber material for providing a cushion effect at any point of said barebone ball after vulcanization.

13. The method, as recited in claim 9, wherein said ball casing is made of rubber material for providing a cushion effect at any point of said barebone ball after vulcanization.

14. The method, as recited in claim 10, wherein said ball casing is made of rubber material for providing a cushion effect at any point of said barebone ball after vulcanization.

15. The method as recited in claim 1, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.

16. The method as recited in claim 2, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.

17. The method as recited in claim 9, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.

18. The method as recited in claim 10, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.

19. The method as recited in claim 13, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.

20. The method as recited in claim 14, wherein, in the step (d), said outer cover panels are adhered on said outer circumferential surface of said ball casing of said barebone ball.