BALL WITH INTERIOR REINFORCEMENT PATCHES

Soccer balls, volley balls and the like are provided with interior reinforcing patches disposed over the stitched seems to prevent thread breakage, seam separation and water incursion while at the same time enhancing the softness and durability of the ball's structural panels.

TECHNICAL FIELD

The present invention is generally directed to balls for sporting activities. More particularly, the present invention is directed to soccer balls and to volleyballs. Even more particularly, the present invention is directed to sports balls and their manufacturing processes. Even more particularly, the present invention is directed to improvements in the processes and structures employed in balls that are sewn by machine.

BACKGROUND OF THE INVENTION

Traditional hand sewn balls are produced by joining cut panels together by hand sewing by with thread which is thick and strong. Each stitch is pulled by hand by a skilled worker to make the stitch tighter and secure it from opening so as to withstand the pressure of an inflated inner bladder especially during striking and kicking the ball during play. The typical sports ball is produced using a latex rubber bladder without having any rewound thread around it to prevent its expansion during use. The panels are joined by hand sewing and, because of this, are strong enough to bear the stresses of an inflated inner bladder pressure.

During the hand sewing process, workers use small strands of threads to stitch panels together and they have to use many strands before a ball is completed. Each time a new strand is used, it must be secured properly with previous stitching which tends to produce knots. These strands are employed to prevent the stitching from unraveling during play. However, some workers leave it without properly securing it with a knot. As a result, ball stitching is opened up and bladder pressure inside the ball pushes the bladder outwards and thus making the ball not usable for play.

Another drawback is that, since the thread used in hand sewing is often thick and sometimes two strands of thread are tied together with each other and they form a thick knot of thread which sticks out inside the ball against the inflated bladder. This often causes a leak in the inflated bladder body.

There is also a problem with machine sewn balls that include a thread rewound bladder. Traditional machine sewn balls that are produced using a sewing machine to join the ball panels together do not produce balls that are strong enough to sustain inflated inner bladder pressure and therefore an inner bladder is provided with a rewound web of yarn or thread all around the bladder which prevents its outward expansion and the exertion of pressure on the machine sewn exterior cover. This helps to prevent the tearing of the stitching on the exterior cover during kicking or striking during play.

Balls with a rewound web of yarn or thread all around the bladder do not provide a lively feel during play. In this case the exterior machine sewn cover is provided with a thick foam to improve its softness and feel. Its softness and feel is limited to the thickness of the outer foam covering. Having an inner bladder with a web of yarn wound around it does not promote flexing and does not give a lively feel and response to the player when the ball is kicked or struck.

In another embodiment of sports balls a machine sewn ball may be provided with a simple bladder without having any interior rewind covering of a thread web over the bladder to control its expansion. However, this ball is not particularly strong because the inner inflated bladder pressure is applied directly on the machine sewn thread joints and thus the stitches are easily ripped and torn apart during play while striking or kicking. In such a structure, the interior bladder does not have any kind of covering over it to stop its expansion. Therefore most of the pressure produced by the inflated bladder is applied directly on the ball's exterior cover and the sewing. Due to this structure, during play or otherwise, there can often be an increase in the overall size of a ball which is not acceptable to ball regulatory authorities such as the FIFA (International Federation of Association Football) in case of soccer and the FIVB (Federation Internationale de Volleyball) in case of Volleyball or other regulatory authorities. In this case, the interior bladder does not having any kind of covering on it to stop its expansion.

In yet another sports ball embodiment which has undesirable limitations, one finds a machine sewn ball in which fabric patches are pasted to the bladder to prevent its expansion outward and to stop damage to the machine sewn stitches caused by inflated bladder pressure. This ball has same problem as the one having a rewound thread web around it. The fabric patches in this ball structure are pasted on the bladder; however, this does not permit the bladder to properly flex. Therefore, this does not provide a desired level of feel and responsiveness that is found in a ball having a bladder without any type of cover, whether a web of thread or fabric patches.

In addition, there are other drawbacks commonly found in sports ball manufacture. In particular, in all traditional balls whether hand sewn ball or machine sewn, water is able to penetrate inside the ball during play on wet ground and as a result the ball weight is increased and makes it heavier to play with. Accordingly, in this circumstance, water inside, if not properly dried after play, causes mold inside the ball thus completely damaging the ball. If one tries to seal the joint seams with some form of adhesive from the outside to stop water from seeping into the interior of ball, it is often the case that this adhesive comes off after a few games through wear and tear and contact with the ground. Another disadvantage of adhesive application is that it is difficult to apply an adhesive uniformly on the seams of the ball and to avoid damaging the cosmetic appearance of the ball during the sealing process. Another major problem with all of the hand sewn and machine sewn balls is that, when the thread joining the panels together is torn or when it unravels, it exposes the bladder due to the internal bladder pressure. This forms a gap between sewn panels and therefore ball is deformed and not usable for play. There is yet another big drawback for hand sewn balls is that if a thread is torn off or broken, there is can arise a big gap between panels which is formed due to internal bladder pressure. Particularly during “heading” (striking with the head) in the game of soccer, this can cause injury.

In view of the above there is a need to have a machine sewn sports ball having a stronger exterior cover comprising panel which are stitched together to form a spherical (or other) shape and stitching does not open or break due to internal inflated bladder pressure. From the above, it is therefore seen that there exists a need in the art to overcome the deficiencies and limitations described herein and above.

SUMMARY OF THE INVENTION

The shortcomings of the prior art are overcome and additional advantages are provided through the use of patches disposed over the internal stitched seems of sporting balls such as soccer balls and volley balls. In view of the above there is a need to have a machine sewn ball having stronger exterior cover panels stitched together to form a desired shape and in which thread stitching does not open or break due to internal inflated bladder pressure.

More particularly, the present invention includes a plurality of exterior, stitched together panels sewn at their edges, configured to form a closed volume and forming, by said stitching, raised interior edges at the edges of said panels. The ball also includes an interior bladder which, when inflated, presses up against the panels and the stitching. Lastly, and most importantly, there is provided a plurality of patches adhered to adjacent ones of the panels, on their interior portions, and disposed over the stitching. Depending on the panels used to form an enclosed volume, the patches have shapes intended to cover the stitching.

Accordingly, it is an object of the present invention to protect the interior ball stitching from breaking due to internal inflated bladder air pressure.

It is also an object of the present invention to promote the production of soccer balls, volley balls and the like through the use of machine sewing, as opposed to hand sewing.

It is another object of the present invention to prevent ball deformation in the event that a stitch is broken.

It is also an object to hold panels together, in their place, and thus not allowing the ball to develop a gap between seems because interior fabric reinforcement patch thus holds the panel in place.

It is yet another object of the present invention to stop water from seeping into the body of the ball particularly during play on wet ground.

It is a still further object of the present invention to prevent the growth of mold inside the ball.

It is still another object of the present invention to ensure that the middle part of a reinforcement patch covers the middle portion of two adjacent panel edges to stop water from coming inside the body of the ball.

It is yet another object of the present invention to prevent water seepage into the ball through any apertures produced by the sewing operation.

It is a still further object of the present invention to reduce the need for an interior thread winding.

Lastly, but not limited hereto, it is an even further object of the present invention to cover sewing needle marks.

The recitation herein of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.

DETAILED DESCRIPTION

FIG. 1illustrates to shapes of the panels used in the construction of one form of soccer ball. In this construction, 20 hexagonal panels and 12 pentagonal panels are employed. In particular, there is illustrated hexagonal panel101and pentagonal panel102. Also shown in this figure is the joining together of two of the hexagonal panels by means of stitching103. It is noted that this stitching structure produces raised stitching105on the interior of the ball in its final form (SeeFIGS. 3 and 4). The presence of this stitching plays a significant role in the present invention. Reinforcement patches used in the present invention comprise any suitable material such as a fabric which is punched out from a large sheet of material. The patch is either a single layered or multilayered fabric which comprises any suitable fabric and may exist in a plurality of shapes depending on the pattern of seams on the ball.

FIG. 2is similar toFIG. 1except that it is directed to the construction of a volleyball. In particular, panels201and202are shown and are shown as being sewn together by way of stitching203.FIGS. 12 through 15are also useful to consider along withFIG. 2as these are also directed to the fabrication of volleyballs.

FIG. 3illustrates the construction of a soccer ball using the well-known set of 20 hexagons and 12 pentagons. The hexagonal panels are denoted by reference101and the pentagonal panels are denoted by reference102. In particular, the illustration ofFIG. 3shows the construction of a soccer ball in its inverted form prior to the insertion of the bladder. The bladder is the device used for inflation. Of particular note is raised stitching105which is present on the inside of the completed soccer ball. Also of note is seam107. This is the last seam sewn before the soccer ball is inverted. It is through seam107that bladder109is inserted. SeeFIG. 7. Also shown inFIG. 3is the presence of opening110in one of the panels. It is within this opening that a valve for the bladder is disposed.FIG. 4is similar toFIG. 3except that it is an enlargement and is better descriptive of stitching lines and holes103. The preferred material for the panels is PU, PVC and TPU with a foam and fabric sandwich. Materials such as PU+Foam+Fabric, TPU+Foam+Fabric etc. are employed. Additionally, multiple layers of fabric instead of one are employed. One could employ any suitable combination of material or materials and any type of sandwich of materials or material for the panels. Likewise, patch material is either a singular layer of fabric impregnated with latex rubber or a combination of multiple layers of fabric impregnated with latex rubber. As with the panels, any suitable material is employed.

FIG. 5is particularly relevant for the present invention. In particular, there are shown two versions of patches,150and151, intended for being placed over raised threaded portions105. These are the patches employed in the present invention for all of the purposes recited above. Patch151illustrates an embodiment of the invention which is usable because sewn edges are often higher at the corners of each panel. By employing patch design151, the problem of dealing with wrinkles that are formed at these corners or vertices is solved. Patch design151is provided with V-shaped cuts, as shown, so that when patches sit along the seams where three panels meet, the patches do not form wrinkles.

FIG. 6is also particularly relevant in understanding the structure and features of the present invention. In particular,FIG. 6illustrates the placement of patches150or151over sewing seams or edges105. Note that the presence of overlap between adjacent patches is visible in this figure. It is observed that the ball shown inFIG. 6represents a soccer ball with 20 hexagonal panels and 12 pentagonal panels. Clearly this figure illustrates the interior structure of a soccer ball prior to its being inverted through open seam107. A patch of reinforcement fabric150is applied over each machine sewn panel stitch joint105with adhesive to better secure the stitched panels together. Fabric reinforcement patches cover each adjacently sewn panel joint and thus forms a network of reinforced ridges to further secure the stitching and to withstand pressure from an inflated bladder. This relieves pressure on the machine sewn stitches which are often not strong enough and are not able to withstand bladder pressure. The patches link one panel body to another panel body going across the sewing ridges and bonds them together in such a way that inflated bladder pressure is eliminated on the stitches. The patches act as a strong barrier to absorb pressure and to hold an inflated bladder inside without damage and without tearing any stitches during kicking during play.

FIG. 7illustrates the exterior of a soccer ball with 20 hexagonal panels and 12 pentagonal panels wherein bladder109is in the process of being inserted through seam107(seeFIGS. 3, 6 and 10). Also visible is opening110for an inflation valve.FIG. 8illustrates the process of stitching up the last seam after bladder109is disposed through seam107. Needle and thread (121and120, respectively) are used to close up seam107.FIG. 9illustrates completed soccer ball100. The patches of the present invention are not visible in this Figure.

FIG. 10is similar toFIG. 6except that it is directed to the construction of a soccer ball in which only pentagonal panels are used in its construction. Here the pentagonal panels are denoted by reference numeral104.FIG. 10also illustrates seem107through which an inflatable bladder is inserted before the ball is turned inside out.FIG. 11is similar toFIG. 10except that it illustrates the internal structure of a soccer ball prior to placement of patches150.

FIGS. 12 through 15represent the structures employed in the present invention when they are used for the construction of a volleyball. A completed volleyball is illustrated inFIG. 15. In the construction of a volleyball differently shaped panels,201,202and203, are employed. SeeFIG. 12. In the construction of a volleyball sewn ridges205are produced by the sewing operation which, like the construction of a volleyball, is preferably done by machine. It is clear from the illustration that there is shown a volleyball's interior prior to the application of any reinforcing patches and prior to its inversion and the insertion of a bladder.FIG. 13illustrates the placement of reinforcing patches250and251. As discussed above, patch251also includes V-shaped notches to better accommodate the higher ridge portions that occur at panel vertices.FIG. 14illustrates the placement of patches260which are sized to accommodate the network of internal ridges produced in the construction of a conventional volleyball. A completed volleyball200is illustrated inFIG. 15.

The reinforcement patches employed in the present invention are made of any suitable fabric or combination of fabrics. Additionally, it is noted that patches are disposed in either singular or multiple layers. Patches comprise a plurality of shapes depending on the stitching pattern employed in ball fabrication. Patches are disposed either in a fashion in which their ends overlap or in which they do not touch. However, in preferred embodiments, overlapping is preferred. The panels themselves comprise any suitable ball material and/or any combination of suitable materials used to make any type of sports ball. While the present description is generally directed to the construction of soccer balls and volley balls, by selecting panels of various shapes it is possible to construct a sports ball of any desired shape. However, spherical shapes more common and are easier to design and fabricate. As described above, particularly with reference toFIGS. 7 and 8, all of the panels are sewn together, except for certain final panels, which are stitched together lastly so as to allow the ball to be turned inside out.

These reinforcement patches work as an interior safety reinforcement layer between one panel to another and thus this whole network of reinforcement patches inside of ball panels make it one uniform interior layer protecting the sewing parts and at the same time attaching themselves to the flat part of panel that reduces pressure on stitches and sewing parts.

In preferred embodiments of the present invention, all of the reinforcing patches connect with each other by overlapping each other, as shown inFIGS. 6, 10 and 14, thus forming a single reinforcing layer underneath (looking from the outside) the sewing ridges of the panels.

In another preferred embodiment, after the ball is completed, a thin adhesive is deployed along the seams; the adhesive then seeps through the seams and ends up on the internal patches. In this way, the adhesive strengthens the connection between adjacent seams along the panel edges. Thus, the internal patches forming a bond of three parts: thread, panel edges and internal patches. This further secures seam strength and at the same time helps to make the seams more waterproof.

While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the spirit and scope of the invention.