Systems and methods for producing a sports ball

A method for forming a plurality of panels, which may comprise cutting a plurality of outer layers cutouts corresponding to a respective shape for each of the plurality of panels, applying indentation on foams of each of the plurality of panels, placing them in respective corresponding mold and applying pressure to each of the corresponding molds for thirty to forty seconds to form finalize panels. Method may further comprise forming a pre-finalized ball by attaching the plurality of the panels including the bladder valve panel to a bladder and respective edges to each of the plurality of the panels to respective edges of adjacent panels of the plurality of the panels, and placing the pre-finalized sports ball in a mold and applying heat to the pre-finalized sports ball.

PRIORITY INFORMATION

The This application is a non-provisional application of Provisional Patent Application No. 63/651,415, filed on May 24, 2024, entitled “Systems and Methods for Producing a Sports Ball,” which is incorporated herein by reference in its entirety.

TECHNICAL FIELD

The present disclosure relates generally to a ball and a method for manufacturing a ball. More particularly, and without limitation, the present disclosure relates to structures and methods for manufacturing a sports ball.

BACKGROUND

Conventional thermos-bonded sports balls with internal bladder have numerous drawbacks including required numerous complicated steps in their manufacturing taking longer time and creating unnecessary wastage during these numerous processes and investment in machinery for every step of manufacturing. Therefore, for increasing manufacturing capacity, there is a need for significantly increasing manpower and cost.

Exemplary embodiments, consistent with the present disclosure, therefore, aim to resolve the aforementioned problems including allowing for the same quality and consistency of balls during usage but allowing for more cost-effective and time effective manufacturing mechanisms, among others.

SUMMARY

An object of the invention is to provide a new and improved sports ball having a high performance, synthetic leather balls that are of high quality but are manufactured utilizing exemplary approaches, providing high durability while also providing manufacturing cost-efficiency in terms of time and costs.

In an exemplary embodiment, a manufacturing method of a sports ball is provided. Exemplary methods comprise the steps of a manufacturing method of a sports ball, comprising the steps of forming a plurality of panels, comprising forming an outer layer for the plurality of panels, comprising forming the outer layer by attaching foam to a Polyurethane (PU) layer, forming cutouts corresponding to a respective shape for each of the plurality of panels from the outer layer, forming pre-mold cutouts by creating one or more foam indentations on each of the respective cutouts by applying a laser to the foam of each respective cutout. forming each respective panel of the plurality of panels by placing each of the pre-mold cutouts in a corresponding mold, wherein a shape of the corresponding mold corresponds to a shape of a finalized panel, a mold comprising of an upper mold portion and a lower mold portion, the lower mold portion comprising a cavity in a desire shape of a respective panel, the upper mold portion comprising a pressing part corresponding to shape of the cavity. And forming each respective panel in each respective corresponding mold by applying pressure utilizing the upper mold portion applying heat for thirty to forty seconds. In an exemplary embodiment, the method may further comprise creating a bladder valve panel by inserting a valve in one of the plurality of created panels, forming a pre-finalized ball by attaching the plurality of the panels including the bladder valve panel to a bladder and respective edges to each of the plurality of the panels to respective edges of adjacent panels of the plurality of the panels, and placing the pre-finalized sports ball in a mold and applying heat to the pre-finalized sports ball, wherein the applying heat to the pre-finalized sports ball comprises applying 70 degrees Celsius for thirty seconds to sixty seconds.

DETAILED DESCRIPTION

A sports ball is traditionally made up of two major components, a bladder for air and a cover of panels. Embodiments consistent with the present disclosure enhance the performance of a sports ball by providing a method and structure for efficiently utilizing manufacturing techniques for forming sports balls. Specifically, exemplary embodiments provide for utilizing unique methods to form unique structures which allow for efficient produced thermo-bonded balls, in terms of monetary and time resources.

FIG.1Aillustrates an exemplary method100for manufacturing a sports ball, consistent with one or more exemplary embodiments of the present disclosure.

With further details, with respect to method100, step102may comprise of forming a plurality of panels, consistent with one or more exemplary embodiments of the present disclosure.

In an exemplary embodiment,FIG.1Billustrates flowchart110comprising details of step102.

In an exemplary embodiment, step112may comprise of forming an outer layer for the plurality of panels, comprising forming the outer layer by attaching foam to a Polyurethane (PU) layer. In an exemplary embodiment, an exemplary outer later may be formed by attaching exemplary foam to a PUL layer utilizing latex.

In an exemplary embodiment,FIG.2displays such an outer layer200, where latex204is utilized to attached foam206to PU layer202. In an exemplary embodiment, foam206may have a thickness of 4 mm to 5 mm. In an exemplary embodiment, outer layer200may have a thickness of 5 mm to 6.5 mm.

In an exemplary embodiment, step114may comprise of forming cutouts corresponding to a respective shape for each of the plurality of panels from the outer layer. In an exemplary embodiment, step114may be understood in the context ofFIGS.2,3A, and3B.

In an exemplary embodiment, as described above,FIG.2displays an outer layer200.

In an exemplary embodiment,FIGS.3A-3Dare illustrations of an exemplary scenario for cutting out a plurality of cutouts, according to an embodiment of the present disclosure. As shown inFIG.3A, required panel shapes302and304may be cut from layer300using conventional ball cutting knives. Alternatively required shapes302and304may be cut from layer300utilizing a laser. In an exemplary embodiment, an exemplary laser may comprise of an exemplary CO2 laser which may be configured to allow for such cutting. In an example embodiment, layer300may be an outer layer for panels of a sports ball similar to outer layer200, consistent with exemplary embodiments of the present disclosure.

FIG.3Billustrates exemplary cutouts312and314that may be cut from outer layer300, for example from required panel shapes302and304. In this exemplary scenario, cutouts312and314may represent a cutout of outer layer300. In an exemplary embodiment, for each respective ball, there may be 24 to 32 cutouts which may all be transformed as explained in context of further steps below to collectively form the outside covering of a sports ball. In an exemplary embodiment, there may be 12 or less cutouts.

As shown inFIG.3C, required panel shapes306and308may be cut from layer300using conventional ball cutting knives, similar to as shown inFIG.3A. Alternatively required shapes306and308may be cut from layer300utilizing a laser, similar to as shown inFIG.3A.

FIG.3Dillustrates exemplary cutouts316and318that may be cut from outer layer300, for example from required panel shapes306and308. In this exemplary scenario, cutouts316and318may represent a cutout of outer layer300. In an exemplary embodiment, cutout316and318may be panel shapes which are meant to have an aesthetic look of multiple sports balls panels when in fact they are a singular panel. In an exemplary embodiment, a plurality of these types of panels formed utilizing exemplary cutouts may form a sport ball.

In an exemplary embodiment, method100may further comprise of step116. In an exemplary embodiment, step116may comprise of forming pre-mold cutouts by creating one or more foam indentations on each of the respective cutouts by applying a laser to the foam of each respective cutout. In an exemplary embodiment, details of step116are provided inFIG.1Ccomprising method140. In an exemplary embodiment, details of method140are illustrated in further detail in combination with accompanying description ofFIGS.4A-C,5A-C,6A-C,7A-C, and8A-C.

In an exemplary embodiment, step142may comprise of determining indentation lines. In an exemplary embodiment, indentation lines may comprise of exemplary imaginary (or real) lines on an exemplary surface of exemplary foam where indentations are to be created.

In an exemplary embodiment,FIGS.4A-Cillustrated various indentation lines as illustrated on an outer layer, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment,FIG.4Aillustrates a singular indentation line410on cutout400(similar to exemplary cutout302), whileFIG.4Billustrates respective indentation lines410and412respectively on cutout400. In an exemplary embodiment, respective indentation line410may be a distance of 1.5 to 2 mm away from exemplary outside edges of cutout302. In an exemplary embodiment, the distance may be in direction of an exemplary biggest plane of a surface of an exemplary cutout. In an exemplary embodiment, an indentation line412may be a distance of 1.5 to 2 mm away from indentation line410in a direction away from indentation line away from edges of cutout302(or towards the center of cutout302). In an exemplary embodiment, there may be additional indentation lines, with each a distance from 1.5 to 2 mm from a closest indentation line. In an exemplary embodiment,FIG.4Cillustrates an additional indentation line414in addition to indentation lines410and412. In an exemplary embodiment, there may be additional indentation lines included between indentation line412and414, each with a distance of 1.5 to 2 mm. from a previous indentation line. In an exemplary embodiment, indentation line414may be parallel to a respective edges of cutout400but may be broken up so it may be present for less than two-thirds of a perimeter if it was constantly present.

In an exemplary embodiment, step144may comprise of forming indentations within foam based on the indentation lines. In detail, after indentation lines are determined/created, in an exemplary embodiment, an exemplary laser may be utilized to former indentations on an exemplary surface of exemplary foam based on exemplary indentation lines. In an exemplary embodiment, an exemplary laser may comprise of a laser produced by utilizing CO2. In an exemplary embodiment, laser may create an exemplary foam indentation on each of the respective cutouts.

In an exemplary embodiment,FIG.5Aillustrates three top views of respective pre-mold-cut outs502,504, and506,FIG.5Billustrates perspective views of pre-mold-cut outs502,504, and506, andFIG.5Cillustrates perspective views of pre-mold-cut outs502,504, and506, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, pre-mold cut out502illustrates an exemplary scenario in which an indentation was formed at indentation line410, pre-mold cutout504represents an exemplary scenario in which indentations were formed at indentation lines410and412, while pre-mold cutout506represents an exemplary scenario in which indentations were formed at indentation lines410,412, and414.

In an exemplary embodiment, indentations illustrated throughoutFIGS.5A-Cmay have similar properties, but as an illustrative example, indentation510from is described in further detail. In an exemplary embodiment, as illustrated inFIG.5C, an end-to-end distance520in a perspective view of an exemplary foam for an indentation510may be 0.75 to 1.25 mm. Accordingly, in an exemplary embodiment, diameter of an exemplary laser utilized to make an exemplary indentation may be 0.75 to 1.25 mm (accordingly, an indentation may be made of a same size). In an exemplary embodiment, an indentation may have a depth522of up to 3 mm, while the overall thickness524of exemplary cutouts may be in a range of 5 mm to 6.5 mm. Accordingly, based on exemplary indentation lines, in an exemplary embodiment, an exemplary indentation may be present a certain distance from edges of a respective cutout through the periphery of exemplary cutout.

In an exemplary embodiment, as illustrated in pre-mold cutouts504and506, there may be multiple indentations, for example, two to four additional indentations which may be a distance of 1.5 to 2 mm from another indentation. In an exemplary embodiment, an exemplary additional indentation may be present only for part of the indentation line, such as pre-mold cutout506, on an exemplary indentation may have a partial line. That is, indentation530may occur with the same width, but on the periphery of exemplary cutout, it may occur for only part of an exemplary indentation line.

In an exemplary embodiment, method100may further comprise of step118. In an exemplary embodiment, step118may comprise of placing each of the pre-molds cutouts in respective corresponding mold. In an exemplary embodiment, respective molds may have physical properties based on desired finalized shapes of finalized panels (as discussed in further detail below).

In an exemplary embodiment, method100may further comprise of step120. In an exemplary embodiment, step120may comprise of forming each respective panel in each respective corresponding mold by applying pressure utilizing the upper mold portion and applying heat for thirty to forty seconds. In further detail, in an exemplary embodiment, an exemplary upper mold portion may apply downwards force while at the same time, heat may be applied for thirty to forty seconds comprising a temperature of 70 degrees Celsius or more.

Details of steps118and120are explained in the context of,6A, and6B. In an exemplary embodiment,FIGS.6A and6Billustrates cross-sections of exemplary mold600in two exemplary scenarios, consistent with exemplary embodiments of the present disclosure. In an exemplary embodiment,FIG.6Aillustrates exemplary mold600is illustrated in a pre-pressed state. In an exemplary embodiment, mold600may comprise of upper mold portion602and a lower mold portion604. In an exemplary embodiment, exemplary mold600may correspond to shape of a desired finalized panel (as discussed in further details below). In an exemplary embodiment, mold600may correspond to respective outer layer cutout302. In an exemplary embodiment, upper mold portion602may have a base part606and a pressing part608. In an exemplary embodiment, pressing part608may correspond to shape of a desired finalized panel and may also correspond to cavity610within lower mold portion604. In an exemplary embodiment, end-to-end distance612of cavity610may be at least 0.5 mm more than end-to-end distance614of pressing part608. In an exemplary embodiment, end-to-end distance612of cavity510may be 77.5 mm and end-to-end distance614of pressing part608may be 77 mm. This may allow pressing part608to be fully enveloped within cavity612while applying pressure to exemplary outer layer included within. In an exemplary embodiment, a top part620of lower mold portion604, may have an end-to-end distance of 84.5 mm. Accordingly, an exemplary pre-mold panel622with an end-to-end distance of 84.5 may be placed there. As illustrated, in an exemplary embodiment, pre-mold panel622may have two respective indentations. In an exemplary embodiment, cavity610may have a cavity depth616of 22.5 mm. In an exemplary embodiment, pressing part608may have a height of 18 mm. Accordingly, when an exemplary outer layer with a thickness of 5 to 6.5 mm is present within cavity612, pressing part608would be able to apply pressure to an exemplary outer layer.

In an exemplary embodiment,FIG.6Billustrates exemplary mold600in a second scenario, consistent with one or more exemplary embodiments of the present disclosure. Specifically,FIG.6Billustrates mold600in a pressed state. Specifically, upper mold portion602applies pressure to pre-mold panel622while it is contained within lower mold portion604. In an exemplary embodiment, as upper mold portion602applies pressure to pre-mold panel, heat may be further applied by a heat source.

In an exemplary embodiment,FIG.6Cillustrates a panel formed by utilizing mold600, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, panel630may have an end-to-end distance632or 78.5 mm. That is, cavity614may have a lesser end-to-end distance than the finally produced panel because after being taken out of an exemplary mold, an exemplary panel may expand close to one millimeter.

In an exemplary embodiment,FIGS.7A and7Band illustrate a multiple panel mold, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, mold700may be a singular panel but may have an appearance of multiple panels. In an exemplary embodiment,FIG.7Aillustrated a side view of mold700. In an exemplary embodiment, mold700may be similar to mold500, and may comprise of upper mold portion702and a lower mold portion704which may be functionally and structurally similar to upper mold portion502and a lower mold portion504. In an exemplary embodiment, aesthetic panel bumps706may be a plurality of embossing seam protrusions, that is, a part of an exemplary mold which is raised from a lower surface of an exemplary mold allowing for compression to be applied, allowing for exemplary seam lines to be created. In an exemplary embodiment, exemplary seam lines may allow for giving an impression that multiple panels are formed when, in fact, a long elongated singular panel may be present with one singular panel. In an exemplary embodiment,FIG.7Billustrates a top view of lower mold portion704.

In an exemplary embodiment,FIGS.8A and8Billustrate cutouts800and802which may correspond to multiple panel shapes, consistent with one or more exemplary embodiments. In an exemplary embodiment, cutout800may have indentation lines810while cutout802may have indentation lines820and822. In an exemplary embodiment, there may be additional indentation lines as discussed above in context ofFIG.4A-C.

In an exemplary embodiment,FIGS.9A and9Billustrate an exemplary finalized panel900which may be produced by utilizing mold700on exemplary cutout800, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, finalized panel900may have indentions902that may be created based on indentation lines810.

In an exemplary embodiment, method100may further comprise of step122. In an exemplary embodiment, step122may comprise of creating a bladder valve panel by inserting a valve in one of the plurality of created panels. In further detail, in an exemplary center of an exemplary panel, such as for example, finalized panel750, a hole may be made into which an exemplary valve may be attached.

In an exemplary embodiment,FIG.10illustrates exemplary an exemplary bladder valve panel similar to as produced in context of step122, consistent with exemplary embodiments of the present disclosure. A bladder valve panel may refer to an exemplary panel of a soccer ball that has a bladder attached to it and contains a valve for filling air into the bladder or for deflating the bladder. For example, an exemplary finalized panel750. For example,FIG.10, illustrates a bladder valve panel1000, consistent with exemplary embodiments of the present disclosure. In an exemplary embodiment, a cutout of bladder valve panel1000may be similar to finalized panel750. In further detail to step,122, first, a cavity may be created in the middle of an exemplary display panel where an exemplary valve may be inserted. In an exemplary embodiment, conventional methods such as punching a hole by hand or by a machine one by one. Accordingly, cavity1004may be formed through which an exemplary valve (of an exemplary bladder). Therefore cavity1004may be located on bladder valve panel1000.

Now referring back to method100, in an exemplary embodiment, method100may further comprise step104comprising forming a pre-finalized ball by attaching the plurality of the panels including the bladder valve panel to a bladder and respective edges to each of the plurality of the panels to respective edges of adjacent panels of the plurality of the panels. In an exemplary embodiment, further details with respect to step104may be clearly illustrated in combination withFIGS.11A-14C.

In an exemplary embodiment,FIGS.11A and11Billustrate two exemplary bladders1100and1102, consistent with exemplary embodiments of the present disclosure. As illustrated, exemplary bladders1100and1102are both attached to exemplary valve1104. In an exemplary embodiment, exemplary bladder valve panel as described in context of step118may be attached to this valve.

In an exemplary embodiment, bladder1100may comprise a molded rubber or butyl bladder or synthetic rubber that may be laminated with polyester or polyester cotton cloth strips. In an exemplary embodiment, bladder1102may comprise a molded rubber or butyl or synthetic rubber that may be wound with polyester or nylon threads. In an exemplary embodiment, additional bladders, with restricted circumference properties may be used. In exemplary embodiments, valve1104may be used for inflating or deflating bladders1100and1102. Exemplary bladders aid in providing firmness and roundness to a soccer ball, in addition to serving as an exemplary base on top of which exemplary panels are attached.

Referring back to details of step104, referring to attaching the plurality of the panels to a bladder may include attaching a set of panels to an exemplary bladder. In an exemplary embodiment, this may entail applying a latex or an adhesive all around on an outer surface of an exemplary bladder such as bladder1100and1102. In an exemplary embodiment, an exemplary latex may be applied on each finalized panel of the plurality of panels as well.FIGS.12A-Cillustrate cross-sections of exemplary scenarios with exemplary latex or adhesive applied to exemplary finalized panels, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment, as illustrated inFIGS.12A, finalized panel1200may have adhesive or latex1202applied just on an exemplary bottoms surface (side with exemplary foam formed therein) which is meant to be attached to an exemplary bladder (such as bladders1100or1102). In a second exemplary scenario as displayed inFIG.12B, finalized panel1200may have adhesive or latex1204applied exemplary bottom surfaces (side of finalized panel with exemplary foam formed therein) and also at least half of the sides of finalized panels encompassing exemplary PU cutouts. In an exemplary embodiment, this may allow for two adjacent finalized panels to be connected with each other, in addition to being connected to an exemplary bladder. In an exemplary embodiment,FIG.12Cillustrated such an exemplary scenario, when finalized panel1200with adhesive or latex1204, may be attached or connected to finalized panels1206with adhesive or latex1208. In an exemplary embodiment, finalized panels1200and1206may be formed utilizing similar techniques and their edges may correspond to each other. Furthermore, latex and adhesives120,1204, and1206may be similar in terms of composition but may be applied as illustrated in the respective figures.

In an exemplary embodiment, bladder valve panel would be attached corresponding to an exemplary location of an exemplary valve on an exemplary bladder and remaining plurality of panels would be attached accordingly.

FIGS.13A and13B, illustrate exemplary stages of forming a pre-finalized balls, consistent with one or more exemplary embodiments of the present disclosure. In an exemplary embodiment,FIG.13Aillustrates plurality of panels1302and plurality of panels1304being placed respectively around bladders1100and1102. In an exemplary embodiment, plurality of panels1302and1304may be exemplary panels formed utilizing step102of method100. For simplicity, plurality of panels1302and1302are not illustrated displaying the valve panel but one of ordinary skill in the art would comprehend that one of the panels would be an exemplary bladder valve panel.

FIG.13Bdisplays a finalized ball1310that may comprise an internal exemplary bladder with exemplary plurality of panels attached thereon utilizing an exemplary latex or adhesive. In an exemplary embodiment, plurality of panels may also be attached to each other utilizing an exemplary latex or adhesive. In further detail, adhesives may be attached between respective edges of all the plurality of embossed panels. Therefore, in addition to the respective adhesives attaching the respective plurality of panels to an exemplary surface of an exemplary bladder, exemplary plurality of panels may also be attached to each other. In an exemplary embodiment, once all exemplary embossed panels for an exemplary sports ball are attached to an exemplary bladder utilizing an adhesive or glue, a bladder contained within a soccer ball may be completely filled with air.

In an exemplary embodiment, step106may comprise placing the pre-finalized sports ball in a mold and applying heat to the pre-finalized sports ball. In an exemplary embodiment, an exemplary pre-finalized sports ball may be placed in a heated molding machine (not shown) which is round in the finalized shape of a soccer ball. Heating under pressure of the inner cover of a molding machine may then be applied to the soccer ball for providing a permanent shape and thermo-bonding all of the elements contained within an exemplary mold for form an exemplary soccer ball.

In an exemplary embodiment, an exemplary soccer ball may be molded at 70 degrees Celsius for thirty seconds to sixty seconds. Accordingly, a total of sixty seconds of heat of 70 degrees Celsius may be applied to the soccer ball. Therefore, an exemplary the ball sets uniformly from outside through the pressure generated owing to the hot mold and inside due to the pressure from the bladder. In an exemplary embodiment, this may aid in providing a permanent shape to a sports ball and strengthen its bond on whole.

In an exemplary embodiment, one or ordinary skill in the art would comprehend, that an exemplary plurality of panels may not be restricted to shapes as illustrated in some exemplary embodiments, but any combination of individual panels which may form exemplary of plurality of panels which in combination can be attached to exemplary bladders to form a pre-finalized ball.FIGS.14A-Cillustrated exemplary panel shapes that may form an outer covering of an exemplary soccer ball, consistent with one or more exemplary embodiments of the present disclosure. For example, a plurality of exemplary panels with shapes of panels1402,1404, and1406as illustrated inFIG.14Amay form an exemplary outside covering of an exemplary soccer ball. Similarly, a plurality of exemplary panels with shapes of panels1408,14010,1412, and1414as illustrated inFIG.14Bmay form an exemplary outside covering of an exemplary soccer ball. Additionally, a plurality of exemplary panels with shapes of panels1416,1418,1420, and1422as illustrated inFIG.14Cmay form an exemplary outside covering of an exemplary soccer ball. In an exemplary embodiment, each exemplary panel displayed inFIGS.14A-14Cmay be formed utilizing step102of method100. Accordingly, an exemplary mold's shape would be similar to required panel shape but the principles as described in exemplary embodiments may remain consistent.

In any exemplary embodiments, any seams in an exemplary ball between exemplary embossed panels may be sealed by application of sealants before or after molding. Exemplary sealants may include polyurethane liquids among others.

In an exemplary embodiment, exemplary soccer balls manufactured according to exemplary methods aid in reducing manufacturing costs significantly, while at the same time, the ball rebounds, has water resistance/absorption, and has abrasion properties that are superior to the characteristics of current hand stitched and thermos-bonded balls. Furthermore, exemplary thermo-bonded balls may allow for intricate designs and graphics to be applied directly to the surface of the ball, resulting in visually appealing and professional appearance.

In an exemplary embodiment, exemplary thermos-bonded panels utilized to form a sport ball utilizing exemplary approaches may be applied in any types of balls that utilize panels and bladders, such as footballs, rugby balls, volleyballs, water polo balls, handballs etc.