Patent Publication Number: US-9844706-B2

Title: Inflatable game ball panel construction

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of application Ser. No. 13/778,170, filed Feb. 27, 2013, which is hereby incorporated by reference in its entirety. 
    
    
     INTRODUCTION 
     The present disclosure relates generally to inflatable game balls, and more specifically, to inflatable game ball panel construction using different sized panel layers. Inflatable game balls, including basketballs, footballs, soccer balls, and volleyballs, may include an outside cover with an inflatable bladder on the inside. When the inflatable bladder fills with air, the outside cover may stretch to some degree to reach a fully inflated condition. In the case of footballs made of natural leather or hide, the outside cover can exhibit variations in the amount of stretching due to inherent differences in the degree or amount of stretch between different pieces of leather. As a result, two footballs having covers made of identically sized pieces may have slightly different dimensions when fully inflated to the same internal pressure. 
     SUMMARY 
     An inflatable game ball, or game ball assembly, is provided. The inflatable game ball includes a cover formed from a plurality of panel segments that are attached along peripheral edges. Each panel segment of the cover includes an outer panel portion and an inner panel portion. 
     The outer panel portion having a first shape and a first size, and the inner panel portion having the first shape and a second size. The second size of the inner panel portion is smaller than the first size of the outer panel portion. The outer panel portion is joined with the inner panel portion, such that a peripheral edge of the outer panel portion is aligned, and parallel, with a peripheral edge of the inner panel portion. 
     An inflatable bladder is disposed within the cover, the inflatable bladder being configured to move between a deflated condition and a fully inflated condition. When the inflatable bladder is in the deflated condition, an interior surface of the outer panel portions of the cover is separated a first distance apart from a top surface of the inner panel portions of the cover; and, when the inflatable bladder is in the fully inflated condition, the interior surface of the outer panel portions of the cover is in contact with the top surface of the inner panel portions of the cover. 
     The above features and advantages, and other features and advantages, of the present invention are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the invention, which is defined solely by the appended claims, when taken in connection with the accompanying drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the disclosure. Moreover, in the figures, like reference numerals designate corresponding parts throughout the different views. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a schematic view of an exemplary embodiment of a process of constructing an inflatable game ball in the form of a football; 
         FIG. 2  is a schematic view of an exemplary embodiment of a process of constructing a football using panel layers having different sizes; 
         FIG. 3A  is a top plan view of exemplary embodiments of panel layers having different sizes for use in constructing a football; 
         FIG. 3B  is a top plan view of exemplary embodiments of panel layers having different sizes for use in constructing a football; 
         FIG. 4  is a schematic view of an exemplary embodiment of a panel layer for use in constructing a football; 
         FIG. 5  is a schematic view of an exemplary embodiment of a process of joining panel layers for use in constructing a football; 
         FIG. 6  is a schematic view of an exemplary embodiments of a process of joining panel layers along corresponding peripheral edges; 
         FIG. 7  is a schematic view of an exemplary embodiment of a panel segment for a football; 
         FIG. 8  is a cross-section view of an exemplary embodiment of a panel segment for a football; 
         FIG. 9  is an exploded view of an exemplary embodiment of an alignment guide for use in constructing a football; 
         FIG. 10  is a schematic view of an exemplary embodiment of an alignment guide and panel segment; 
         FIG. 11  is an exploded view of an exemplary embodiment of a football; 
         FIG. 12  is a schematic view of an exemplary embodiment of a process of joining multiple panel segments to form a cover for a football; 
         FIG. 13  is a schematic view of an exemplary embodiment of a football formed of multiple panel segments; 
         FIG. 14  is a cross-section view of an exemplary embodiment of a football illustrating panel layers and an inflatable bladder in the process of being inflated; 
         FIG. 15  is a cross-section view of an exemplary embodiment of a football illustrating panel layers and an inflatable bladder in a fully inflated condition; 
         FIG. 16  is a top plan view of exemplary embodiments of panel layers having different sizes for use in constructing a soccer ball; 
         FIG. 17  is an exemplary embodiment of panel segments for a soccer ball; and 
         FIG. 18  is an exemplary embodiment of a soccer ball formed of multiple panel segments. 
     
    
    
     DETAILED DESCRIPTION 
     The various embodiments described herein relate to an inflatable game ball, particularly, but not necessarily, an inflatable game ball in the shape of a spheroid and/or a prolate spheroid. In an exemplary embodiment, a prolate spheroidal inflatable game ball may be pointed at the ends, for example as is typically used in American football. While the pointedness of an inflatable game ball typically used to play American football, including footballs approved for use in the NFL, NCAA, high school or other leagues, causes it to differ from a true geometric prolate spheroid, such footballs are generally considered to be prolate spheroidal balls, and are encompassed by that term as used herein. 
     In other embodiments, prolate spheroidal inflatable game balls may be configured with shapes that correspond to balls used with other sports, including, but not limited to rugby, Australian rules football, and other sports using a ball having an oblong or elliptical spheroidal shape. 
       FIGS. 1-15  illustrate an exemplary embodiment of a process of constructing an inflatable game ball and an inflatable game ball in the form of a football made using the exemplary process.  FIG. 1  illustrates an exemplary embodiment of materials for constructing a football. While the exemplary process described herein is used for constructing a football, similar principles may be applied to the construction of other inflatable game balls, including footballs, soccer balls, basketballs, volleyballs, and other game balls having a cover and inflatable bladder. 
     In some embodiments, a cover for a football may be made of multiple individual panel segments. In one embodiment, a cover for a football may be made of four individual panel segments. In other embodiments, however, a larger or smaller number of panel segments may be used to form the cover. A cover may be made of a variety of materials, including, but not limited to natural leather or hide, synthetic leather, woven and non-woven fabrics, rubber, plastics, or any other materials known in the art. In some cases, different materials may be used for different portion of a cover. 
     In an exemplary embodiment, an outer layer for a cover of a football may be made of an outer layer material  100 . In this embodiment, outer layer material  100  is a natural leather or hide material having a textured surface  102 . In other embodiments, outer layer material  100  may include synthetic leather or other suitable materials for a cover, described above. In one embodiment, a first pattern  104  that corresponds to a desired shape and size of the panels forming the outer layer of the cover of the football may be provided on outer layer material  100 . 
     In some embodiments, a cover of a football may further include an inner layer or a backing layer that is associated with the outer layer of the cover. In an exemplary embodiment, an inner layer for a cover may be made of an inner layer material  110 . In this embodiment, inner layer material  110  is a woven or non-woven textile material, such as cotton, nylon or polyester, having a top surface  112 . In other embodiments, inner layer material  110  may include canvas or other fabrics, rubber, or other suitable materials for a cover, described above. In one embodiment, a second pattern  114  that corresponds to a desired shape and size of the panels forming the inner layer or backing layer of the cover of the football may be provided on inner layer material  110 . 
     In an exemplary embodiment, first pattern  104  associated with an outer panel layer may be larger than second pattern  114  associated with an inner panel layer. As will be described in more detail below, a method of football constructing using panel layers having different sizes can assist with providing footballs having more consistent dimensions when fully inflated. 
     Referring now to  FIG. 2 , an exemplary embodiment of a process for forming a panel segment of a cover of a football is illustrated. In some embodiments, a first outer panel portion  200  may be an outer panel layer that is removed from outer layer material  100  along first pattern  104 . In one embodiment, first outer panel portion  200  may be associated with a pointed elliptical shape having a first length L 1  in a longitudinal direction between a first end  202  and a second end  204  along a major axis and a first width W 1  in a lateral direction between a first side  206  and a second side  208  along a minor axis. In some embodiments, a first inner panel portion  210  may be an inner panel layer that is similarly removed from inner layer material  110  along second pattern  114 . In one embodiment, first inner panel portion  210  may be associated with a pointed elliptical shape having a second length L 2  in a longitudinal direction between a first end  212  and a second end  214  along a major axis and a second width W 2  in a lateral direction between a first side  216  and a second side  218  along a minor axis. 
     In various embodiments, first outer panel portion  200  and/or first inner panel portion  210  may be removed from outer layer material  100  and/or inner layer material  110  using any known method of removing material along a pattern, for example, by cutting or stamping. 
     In an exemplary embodiment, first length L 1  associated with first outer panel portion  200  may be larger than second length L 2  associated with first inner panel portion  210 . In some cases, first length L 1  may be approximately 2 mm to 8 mm larger than second length L 2 . In one embodiment, first length L 1  may be approximately 4 mm larger than second length L 2 . In other cases, first length L 1  may be less than 2 mm larger than second length L 2  or may be more than 8 mm larger than second length L 2 . In a similar manner, first width W 1  associated with first outer panel portion  200  may be larger than second width W 2  associated with first inner panel portion  210 . In some cases, first width W 1  may be approximately 2 mm to 8 mm larger than second width W 2 . In one embodiment, first width W 1  may be approximately 4 mm larger than second width W 2 . In other cases, first width W 1  may be less than 2 mm larger than second width W 2  or may be more than 8 mm larger than second width W 2 . In different embodiments, the difference in lengths and/or widths between the panels may vary from 0 mm to 12 mm. 
     In some embodiments, the difference between the sizes of the respective panel layers may be substantially uniform around the perimeter of the panel such that the difference between the lengths of the panels is substantially similar to the difference between the widths of the panels. In an exemplary embodiment, the difference between first length L 1  and second length L 2  may be substantially similar to the difference between first width W 1  and second width W 2 . Referring now to  FIG. 3A , a top plan view of first outer panel portion  200  and first inner panel portion  210  having different sizes is illustrated. As shown in this embodiment, the difference in sizes between first outer panel portion  200  and first inner panel portion  210  is substantially uniform around the entire perimeter of the panels. In this embodiment, a first distance D 1  separates the peripheral edges of first outer panel portion  200  and first inner panel portion  210  at both first side  206  of first outer panel portion  200  and first side  216  of first inner panel portion  210  and at first end  202  of first outer panel portion  200  and first end  212  of first inner panel portion  210 . Additionally, in this embodiment, first distance D 1  separates the peripheral edges of other portions of first outer panel portion  200  and first inner panel portion  210  between first side  206 ,  216  and first end  202 ,  212 , as well as other portions around the perimeter of the two panel portions. 
     In some embodiments, first distance D 1  may be substantially equal to approximately half the difference between first length L 1  and second length L 2  and/or first width W 1  and second width W 2 . Accordingly, in some cases, first distance D 1  may be approximately from 1 mm to 4 mm. In one embodiment, first distance D 1  may be approximately 2 mm. In other cases, first distance D 1  may be less than 1 mm or may be more than 4 mm. 
     In some embodiments, the difference between the sizes of the respective panel layers may vary at different portions around the perimeter of the panels such that the difference between the lengths of the panels is different than the difference between the widths of the panels. In an exemplary embodiment, the difference between first length L 1  and second length L 2  may be different than the difference between first width W 1  and second width W 2 . Referring now to  FIG. 3B , a top plan view of first outer panel portion  200  and first inner panel portion  210  having different sizes is illustrated. As shown in this embodiment, the difference in sizes between first outer panel portion  200  and first inner panel portion  210  varies at different portions around the perimeter of the panels. In this embodiment, a difference in width distance DW separates the peripheral edges of first outer panel portion  200  and first inner panel portion  210  at both first side  206  of first outer panel portion  200  and first side  216  of first inner panel portion  210 . In contrast, a difference in length distance DL separates the peripheral edges of first outer panel portion  200  and first inner panel portion  210  at first end  202  of first outer panel portion  200  and first end  212  of first inner panel portion  210 . 
     In some embodiments, difference in width distance DW may be different than difference in length distance DL. In an exemplary embodiment, difference in width distance DW may be larger than difference in length distance DL. In one embodiment, first outer panel portion  200  may be approximately 2 mm larger in length than first inner panel portion  210 , corresponding to difference in length distance DL of approximately 1 mm at each of first end  202 ,  212  and second end  204 ,  214  and first outer panel portion  200  may be approximately 4.5 mm larger in width than first inner panel portion  210 , corresponding to a difference in width distance DW of approximately 2.25 mm at each of first side  206 ,  216  and second side  208 ,  218 . With this arrangement, the proportion of difference in length distance DL to difference in width distance DW may provide sufficient stretch along each of the longitudinal and lateral directions of the cover of the football when in the fully inflated condition such that variations in dimensions of the football are minimized or reduced. 
     In some cases, difference in width distance DW may be approximately from 2 mm to 2.5 mm and difference in length distance DL may be approximately from 0.75 mm to 1.5 mm. In other cases, difference in width distance DW may be less than 2 mm or may be more than 2.5 mm and difference in length distance DL may be less than 0.75 mm or may be more than 1.5 mm. Additionally, in this embodiment, portions of the peripheral edges of first outer panel portion  200  and first inner panel portion  210  between first side  206 ,  216  and first end  202 ,  212 , may vary in a substantially continuous manner from difference in width distance DW at first side  206 ,  216  and different than difference in length distance DL at first end  202 ,  212 . The remaining portions of the peripheral edges disposed around the perimeter of first outer panel portion  200  and first inner panel portion  210  may vary in a substantially similar manner. 
     Accordingly, by varying the difference in sizes along different directions of the panel layers, the amount of stretch along each direction of the constructed football may be limited or restricted by different amounts. With this arrangement, a panel segment may have a larger difference between the respective widths of the panel layers than the difference between the respective lengths of the panel layers to account for a larger amount of stretch that occurs along the width of the panels in the lateral direction than the amount of stretch that occurs along the length of the panels in the longitudinal direction when an inflatable bladder is in a fully inflated condition. 
       FIGS. 4 through 7  illustrate an exemplary embodiment of a process of assembling a single panel segment for use in constructing a football. It should be understood that the process may be repeated to produce additional panel segments that will be combined to form the cover of the football, as will be described below. Referring now to  FIG. 4 , in some embodiments, first inner panel portion  210  may be joined with first outer panel portion  200 . In one embodiment, first inner panel portion  210  may have a band of adhesive  300  disposed along a peripheral edge  302  of first inner panel portion  210 . Adhesive  300  may be a glue, double-sided tape, or other bonding agent. In an exemplary embodiment, adhesive  300  may extend substantially around the entire perimeter of first inner panel portion  210  along peripheral edge  302 . In this embodiment, adhesive  300  may be applied from peripheral edge  302  to an inner periphery  304  located approximately a second distance D 2  from peripheral edge  302 . In one embodiment, second distance D 2  may be approximately 2 mm to 5 mm. In other embodiments, second distance D 2  may be larger or smaller. 
     Adhesive  300  may be any type of adhesive or bonding agent that is configured to hold or otherwise associate first inner panel portion  210  and first outer panel portion  200  together. In some cases, adhesive  300  may be sufficiently strong so as to temporary associate together and to hold the respective panel portions in place so that the panel portions may be joined using a permanent attachment mechanism, for example, stitching or bonding. In other cases, first inner panel portion  210  may be joined to first outer panel portion  200  using other known attachment mechanisms, including, but not limited to bonding, welding, stitching or other temporary or permanent attachment mechanisms. 
       FIG. 5  illustrates first outer panel portion  200  aligned over first inner panel portion  210 . First outer panel portion includes an exterior surface  500  and an interior surface  502 . In this embodiment, exterior surface  500  includes a textured surface to assist with grippability of the cover of the constructed football. First inner panel portion  210  includes a top surface  504  and a bottom surface (not visible). In this embodiment, adhesive  300  is disposed on top surface  504  extending around peripheral edge  302 . However, in some embodiments, first outer panel portion  200  may also have a substantially similar adhesive applied onto interior surface  502  to assist with adhesion between first inner panel portion  210  and first outer panel portion  200 . 
     In an exemplary embodiment, the separate panel portions may be arranged such that interior surface  502  of first outer panel portion  200  is oriented towards top surface  504  of first inner panel portion  210 . In an exemplary embodiment, a peripheral edge  506  of first outer panel portion  200  may be brought together with peripheral edge  302  of first inner panel portion  200 . 
       FIGS. 6 and 7  illustrate an exemplary embodiment of forming a first panel segment  600  by joining first outer panel portion  200  and first inner panel portion  210 . As shown in  FIG. 6 , second end  204  of first outer panel portion  200  is joined at second end  214  of first inner panel portion  210  and peripheral edge  506  is joined with peripheral edge  302  extending along the perimeter of first inner panel portion  210  towards first end  212 . Referring now to  FIG. 7 , in an exemplary embodiment, peripheral edge  506  of first outer panel portion  200  and peripheral edge  302  of first inner panel portion  210  are joined by adhesive  300  along entire perimeter of first inner panel portion  210 . Together, first outer panel portion  200  and first inner panel portion  210  form first panel segment  600 . Adhesive  300  holds peripheral edge  506  in alignment with peripheral edge  302 . With this configuration, the smaller size of first inner panel portion  210  causes first outer panel portion  200  to bulge outward causing exterior surface  500  to have a substantially convex surface  700 . In other embodiments, other attachment mechanisms may be similarly used to join peripheral edge  506  of first outer panel portion  200  and peripheral edge  302  of first inner panel portion  210  along the respective perimeters. 
       FIG. 8  shows a cross-section view of first panel segment  600 . In this embodiment, peripheral edge  506  and peripheral edge  302  are substantially aligned so that both first outer panel portion  200  and first inner panel portion  210  have second width W 2 . However, because first width W 1  of first outer panel portion  200  is larger than second width W 2 , first outer panel portion  200  bulges outward causing exterior surface  500  to have convex surface  700 . In this embodiment, convex surface  700  of first outer panel portion  200  bulges outward by a third distance D 3  from first inner panel portion  210 . In some embodiments, third distance D 3  is approximately equal to the difference between first width W 1  and second width W 2 . In some cases, third distance D 3  may be from 2 mm to 8 mm. In one embodiment, third distance D 3  may be approximately 4 mm. In other cases, third distance D 3  may be less than 2 mm or may be more than 8 mm. 
     In some embodiments, the process described above for aligning peripheral edge  506  of first outer panel portion  200  and peripheral edge  302  of first inner panel portion  210  may be assisted by using an alignment guide.  FIGS. 9 and 10  illustrate an exemplary embodiment of an alignment guide  900  that may be provided to assist with the process of aligning the peripheral edges of first outer panel portion  200  and first inner panel portion  210 . In some embodiments, alignment guide  900  may be a jig or mold that has interior dimensions that correspond to the dimensions associated with first inner panel portion  210 . 
     In this embodiment, the interior dimensions of alignment guide  900  correspond to second length L 2  in a longitudinal direction between a first end  902  and a second end  904  along a major axis and second width W 2  in a lateral direction between a first side  906  and a second side  908  along a minor axis. In an exemplary embodiment, the interior dimensions of alignment guide  900  correspond to second length L 2  and second width W 2  associated with first inner panel portion  210 , described above. 
     In some embodiments, alignment guide  900  may be made of a rigid or semi-rigid material that is configured to hold a shape of the panel portions disposed with an interior  916  of alignment guide  900 . In an exemplary embodiment, alignment guide  900  may include a wall  910  that extends around the perimeter of alignment guide  900 . Wall  910  may include an outer surface  914  and an inner surface  912 . In some cases, alignment guide  900  may include a releasable attachment mechanism, for example, a band or clamp, so that wall  910  may be opened or closed to release the completed panel segment from within interior  916  of alignment guide. 
     In some embodiments, the process of  FIGS. 4 through 7  may be performed using alignment guide  900 . In an exemplary embodiment, first inner panel portion  210  may be placed into interior  916  of alignment guide  900  such that peripheral edge  302  is substantially surrounded by inner surface  912  of wall  910 . Next, adhesive  300  may be applied to one or more of top surface  504  of first inner panel portion  210  and/or interior surface  502  of first outer panel portion  200 . As shown in  FIG. 9 , first outer panel portion  200  has dimensions of first length L 1  and first width W 1  that are larger than the interior dimensions of alignment guide  900 . Accordingly, when first outer panel portion  200  is placed into interior  916  of alignment guide  900  to join with first inner panel portion  210 , inner surface  912  of wall  910  may serve as a guide to constrain movement of first outer panel portion  200 , thereby keeping peripheral edge  302  and peripheral edge  506  aligned so that adhesive  300  may set. In other embodiments, inner surface  912  of wall  910  may similarly serve as a guide to constrain movement peripheral edge  506  of first outer panel portion  200  and peripheral edge  302  of first inner panel portion  210  while other attachment mechanisms are used to join the panel portions along their respective perimeters. For example, in embodiments where welding is used, wall  910  may hold the respective edges in alignment while an ultrasonic welder or other welding apparatus is used to join peripheral edge  506  of first outer panel portion  200  and peripheral edge  302  of first inner panel portion  210 . 
     As shown in  FIG. 10 , in this embodiment, first inner panel portion  210  and first outer panel portion  200  may be placed within interior  916  of alignment guide  900  such that peripheral edge  302  and peripheral edge  506  are bounded by inner surface  912  of wall  910 . First panel segment  600  may then be removed from alignment guide  900 . In some embodiments, multiple panel segments substantially similar to first panel segment  600  may be formed using a similar process, including with or without alignment guide  900 . 
     Referring now to  FIG. 11 , an exploded view of a football constructed with multiple panel segments around an inflatable bladder  1100  is shown. In some embodiments, multiple panel segments substantially similar to first panel segment  600  may be formed using the process described above. In an exemplary embodiment, the multiple panel segments may be joined together to form a cover and be associated with inflatable bladder  1100  to construct a football. In this embodiment, four panel segments are provided to form the cover, including first panel segment  600 , a second panel segment  602 , a third panel segment  604 , and a fourth panel segment  606 . Each of second panel segment  602 , third panel segment  604 , and fourth panel segment  606  may have a substantially similar construction as first panel segment  600 , including an outer panel portion and an inner panel portion having different sizes that are joined along corresponding peripheral edges. 
     In some embodiments, a cover for a football may include multiple panel segments that are stitched, sewed or otherwise joined together along respective edges using adhesive, ultrasonic welding, bonding, or other attachment mechanisms known in the art to form the cover. In some configurations, a cover is formed inside-out, with the interior surface facing outwards and the exterior surface facing inwards. A portion of the respective edges between a pair of adjacent panel segments is left unattached so that an opening is provided to the interior of the inside-out cover. The cover is then turned right-side out by pushing the cover through the opening so that the exterior surface is facing outwards and the interior surface is facing inwards. An inflatable bladder may then be inserted through the opening and inflated. 
     Referring now to  FIG. 12 , an exemplary embodiment of a cover  1200  of a football is illustrated. In an exemplary embodiment, four panel segments, including first panel segment  600 , second panel segment  602 , third panel segment  604 , and fourth panel segment  606  may be joined together to form cover  1200 . In one embodiment, the panels are joined by stitching along the respective adjacent edges of each panel segment. In an exemplary embodiment, the stitching joining the adjacent panel segments is configured to pass through both the outer panel portion and the inner panel portion of each panel segment at or near the adhesively attached peripheral edges. 
     In this embodiment, first panel segment  600  is stitched to third panel segment  604  along a seam  1204 . With this arrangement, the stitching of seam  1204  is configured to pass through first outer panel portion  200 , first inner panel portion  210 , as well as a similar outer panel portion and inner panel portion associated with third panel segment  604 . Each of the remaining panel segments may be similarly joined, such that third panel segment  604  is stitched to fourth panel segment  606  along a seam  1206  and fourth panel segment  606  is stitched to second panel segment  602  (not shown in  FIG. 12 ) along a seam  1208 . Additionally, first panel segment  600  may be stitched to portions of second panel segment  602  along a seam  1202  that extends from each of a first end  1210  and a second end  1212  of cover  1200 . A portion of first panel segment  600  and second panel segment  602  may remain unattached to form an opening  1214 . 
     In some embodiments, opening  1214  may be provided so that cover  1200  may be turned right-side out through opening  1214 . Additionally, opening  1214  may further permit inflatable bladder  1100  to be inserted within cover  1200 . In an exemplary embodiment, inflatable bladder  1100  may be inserted within cover  1200  in a deflated condition. Inflatable bladder  1100  may be filled with air to a particular pressure level to a fully inflated condition. A variety of pressure levels may be appropriate for a ball for any particular game. In some cases, a conventional inflation valve (not shown) that permits the insertion of a typical needle (not shown) that may be connected to a bicycle pump or other suitable air pump (not shown) may be included to allow air to be introduced into inflatable bladder  1100 . This type of inflation valve may be positioned anywhere desirable or convenient on cover  1200  as a designer might select. 
       FIG. 13  illustrates an exemplary embodiment of a finished football  1300 . The dimensions of football  1300  may be configured in accordance with the rules and requirements of different agencies, including, but not limited to the NFL, NCAA, high school or other leagues and/or agencies, which rules and requirements may be changed from time to time. For example, the NFL currently requires that a regulation football have a long axis that measures 11 to 11¼ inches, a long circumference that measures 28 to 28½ inches, and a short circumference that measures 21 to 21¼ inches. The NCAA currently requires that a regulation football have a long axis that measures 10⅞ inches to 11 7/16 inches, a long circumference that measures 27¾ inches to 28½ inches, and a short circumference that measures 20¾ inches to 21¼ inches. Other agencies can have different requirements for the dimensions of a regulation football. Each of the various rules and regulations recognize variations in the dimensions of the football that are permitted between individual footballs that are still considered to be regulation footballs within the rules or regulations. By constructing a football using the process described herein, the amount of variation between individual footballs produced with the required dimensions may be limited or minimized. 
     Referring again to  FIG. 13 , football  1300  includes four panel segments, including first panel segment  600 , second panel segment  602 , third panel segment  604 , and fourth panel segment  606 , described above. Together, the outer panel portions of the respective panel segments of cover  1200  form the exterior surface of football  1300 . Additionally, a lace element  1302  may be included as a functional component of football  1300 , for example to secure parts of adjacent panel segments of cover  1200  to one another. Lace element  1302  may also assist a user in correctly positioning his or her hand to pass or grip football  1300 . In addition, in some cases, lace element  1302  may be included to perform a decorative function for football  1300 . 
     In various embodiments, lace element  1302  may be attached to cover  1200  in any suitable conventional manner, depending on the materials selected for cover  1200  and lace element  1302 . For example, cover  1200  and lace element  1302  may both be made from leather and/or synthetic leather and lace element  1302  may be inserted into perforations in cover  1200 . In some embodiments, reinforcements may be included on the perforations in cover  1200  to prevent lace element  1302  from tearing through cover  1200 . In another example, cover  1200  may be rubber and lace element  1302  may be polyvinyl chloride, rubber, silicone, or other thermoplastic elastomers. In some embodiments, an adhesive might be used to adhere lace element  1302  to the outside of cover  1200 . 
       FIGS. 14 and 15  illustrate cross-section views of football  1300  with inflatable bladder  1100  in a deflated or partially inflated condition ( FIG. 14 ) and a fully inflated condition ( FIG. 15 ). Referring now to  FIG. 14 , inflatable bladder  1100  is shown disposed within the interior of football  1300  surrounded by cover  1200 . In this embodiment, inflatable bladder  1100  is in a deflated or partially inflated condition and is being filled with air from an air pump  1400  via an air valve (not shown) disposed on cover  1200  that is in communication with inflatable bladder  1100 . 
     In some embodiments, when inflatable bladder  1100  is in a deflated or partially inflated condition, the outer panel portion and the inner panel portion of each panel segment may be disposed apart from each other. In an exemplary embodiment, the peripheral edges of the larger outer panel portion are joined along the peripheral edges of the smaller inner panel portion, causing the exterior surface of the outer panel portion to bulge outwards, as described above in reference to first panel segment  600 . In this embodiment, first outer panel portion  200  is disposed a fourth distance D 4  from first inner panel portion  210 . In some embodiments, fourth distance D 4  may be equal to or slightly smaller than the difference between first width W 1  and second width W 2 . In some cases, fourth distance D 4  may be from 2 mm to 8 mm. In one embodiment, fourth distance D 4  may be approximately 4 mm. In other cases, fourth distance D 4  may be less than 2 mm or may be more than 8 mm. 
     In an exemplary embodiment, each of the peripheral edges of first outer panel portion  200  and first inner panel portion  210  forming first panel segment  600  are joined with stitching to each other, as well as the respective peripheral edges of the adjacent panel segment, along seams. In this embodiment, peripheral edge  506  of first outer panel portion  200  is joined with stitching to peripheral edge  302  of first outer panel portion  210  to the respective peripheral edges of the panel portions of second panel segment  602  along seam  1202  and to the respective peripheral edges of the panel portions of third panel segment  604  along seam  1204 . Each of the panel segments, including second panel segment  602 , third panel segment  604 , and fourth panel segment  606  may have a correspondingly similar structure and be joined with stitching in a similar manner as first panel segment  600 . 
     As shown in  FIG. 14 , when air from air pump  1400  begins to inflate inflatable bladder  1100 , the air pushes the inner panel portions, including first inner panel portion  210 , towards the opposite outer panel portion, including first outer panel portion  200 . As inflatable bladder  1100  approaches the fully inflated condition, the inner panel portions will become pushed closer to and/or contact with, the outer panel portions. For example, first inner panel portion  210  may be pushed towards first inner panel portion  200 , thereby reducing fourth distance D 4  separating the panel portions to substantially zero when inflatable bladder  1100  reaches a fully inflated condition. 
       FIG. 15  illustrates inflatable bladder  1100  in a fully inflated condition and in contact with cover  1200  disposed within the interior of football  1300 . In an exemplary embodiment, when inflatable bladder  1100  is in the fully inflated condition, inflatable bladder  1100  will press against each of the inner panel portions of the panel segments disposed about the inside of cover  1200 , including first panel segment  600 , second panel segment  602 , third panel segment  604 , and fourth panel segment  606 . The pressure from inflatable bladder  1100  against the inner panel portions causes the top surface of each inner panel portion to be pushed up against the interior surface of the corresponding outer panel portion. For example, with regard to first panel segment  600 , the top surface of first inner panel portion  210  is pressed up against and abutting the interior surface of first outer panel portion  200 . 
     In some embodiments, due to the difference in the respective sizes of the inner panel portions and the outer panel portions, the inner panel portions may be pushed by inflatable bladder  1100  to fit flush against the outer panel portions. Because the inner circumference of football  1300  is slightly smaller than an outer circumference of football  1300 , the larger size of the outer panel portions and the smaller size of the inner panel portions allows the overall stretching of cover  1200  to be minimized or reduced. 
     For example, as shown in  FIG. 15 , outer circumferential distance C 1  of first outer panel portion  200  on first panel segment  600  is slightly larger than inner circumferential distance C 2  of first inner panel portion  210  on first panel segment  600 . In some embodiments, outer circumferential distance C 1  may be approximately equal to first width W 1  of first outer panel portion  200  less the distance corresponding to the stitched peripheral edge  506  along seam  1202  and seam  1204 . Similarly, inner circumferential distance C 2  may be approximately equal to second width W 2  of first inner panel portion  210  less the distance corresponding to the stitched peripheral edge  302  along seam  1202  and seam  1204 . Accordingly, when inflatable bladder  1100  is in a fully inflated condition, the larger size of the outer panel portions reduces the need for the outer panel portions to stretch to accommodate inflatable bladder  1100  in the fully inflated condition. With this arrangement, the outer panel portions forming cover  1200  are subject to less variations in size caused by differences in stretch properties of the outer layer material  100  used to make first outer panel portion  200 , as well as each other outer panel portion. As a result, the amount of variation between individual footballs produced within the tolerances of the dimensions required by different leagues or agencies may be limited or minimized. In addition, in embodiments where the outer layer material  100  includes a pebbled or textured surface, the reduced amount of stretch applied to the outer panel portions may substantially maintain the quality of the pebbled or textured surface so that grippability of the constructed football is improved. 
     The process of constructing an inflatable game ball using panel portions having different sizes has been described above in reference to constructing a football. However, substantially similar principles may be applied to the construction of any inflatable game ball. Accordingly,  FIGS. 16 through 18  illustrate a process of constructing an inflatable game ball in the form of a soccer ball made using the exemplary process described above with reference to  FIGS. 1 through 15 . Similar principles also may be applied to the construction of other inflatable game balls, including basketballs, volleyballs, and other game balls having a cover and inflatable bladder. 
     In some embodiments, an inflatable game ball having multiple shapes of panel segments may be constructed with one or more of the panels having different sizes according to the process described above. In an exemplary embodiment, an inflatable game ball in the form of a soccer ball may be constructed using panel segments that have at least two different shapes. Referring now to  FIG. 16 , in some embodiments, a cover for a soccer ball may be constructed with at least two different shaped panel segments, including a first shape that is hexagonal and a second shape that is pentagonal. In this embodiment, hexagonal shaped panel portions include a first hexagonal outer panel portion  1600  and a first hexagonal inner panel portion  1610 . Similarly, pentagonal shaped panel portions include a first pentagonal outer panel portion  1620  and a first pentagonal inner panel portion  1630 . 
     In an exemplary embodiment, each of first hexagonal outer panel portion  1600  and first pentagonal outer panel portion  1620  may be cut or removed from an outer layer material that includes any suitable materials disclosed above for outer layer material  100 . In one embodiment, the outer layer material used to form first hexagonal outer panel portion  1600  and first pentagonal outer panel portion  1620  may be a natural or synthetic leather material. In another embodiment, the outer layer material may include felt, wool, or similar materials suitable for indoor soccer ball construction. Similarly, each of first hexagonal inner panel portion  1610  and first pentagonal inner panel portion  1630  may be cut or removed from an inner layer material that includes any suitable materials disclosed above for inner layer material  110 . In one embodiment, the inner layer material used to form first hexagonal inner panel portion  1610  and first pentagonal inner panel portion  1630  may be one or more of a polyester, nylon, or cotton fabric. 
     According to the principles of the construction process described herein, each of the inner layer panel portions may have a substantially similar shape as the outer layer panel portions, but may be a different size. In an exemplary embodiment, the inner layer panel portions may be smaller than the respective outer layer panel portions. As shown in  FIG. 16 , first hexagonal outer panel portion  1600  may be associated with a size defined by a first radius R 1  from a centerpoint to each of the vertices of the hexagon. Simiarly, first hexagonal inner panel portion  1610  may be associated with a size defined by a second radius R 2  from a centerpoint to each of the vertices of the hexagon. In an exemplary embodiment, first radius R 1  may be larger than second radius R 2  such that first hexagonal inner panel portion  1610  is smaller than first hexagonal outer panel portion  1600 . 
     In one embodiment, the pentagonal shaped panel portions may have a similar construction. As shown in  FIG. 16 , first pentagonal outer panel portion  1620  may be associated with a size defined by a third radius R 3  from a centerpoint to each of the vertices of the pentagon. Simiarly, first pentagonal inner panel portion  1630  may be associated with a size defined by a fourth radius R 4  from a centerpoint to each of the vertices of the pentagon. In an exemplary embodiment, third radius R 3  may be larger than fourth radius R 4  such that first pentagonal inner panel portion  1630  is smaller than first pentagonal outer panel portion  1620 . 
     In some cases, the differences in size between each of the panel layer portions may be substantially uniform around the entire perimeter of the respective hexagonal shaped panel layer portions and/or pentagonal shaped panel layer portions. In other cases, the differences in size between each of the panel layer portions may vary along different portions of the perimeter of the panel layer portions, similar to the panel layer portions described above in reference to  FIG. 3B . In still other cases, a combination of uniformly different sizes and varying different sizes of panel layer portions may be used for various panel segments used to form the cover of the soccer ball. With this arrangement, the amount of variation or reduction in stretch of the cover of the soccer ball may be controlled to different degrees at specific portions of the cover. 
     In some embodiments, panel segments used to construct a cover for a soccer ball may be formed using a substantially similar process as described in  FIGS. 4 through 7  above. In other embodiments, one or more alignment guides may be used in a substantially similar manner as described in  FIGS. 9 and 10 . 
       FIG. 17  illustrates an exemplary embodiment of forming a first hexagonal panel segment  1700  by joining first hexagonal outer panel portion  1600  and first hexagonal inner panel portion  1610  along their respective peripheral edges. As shown in  FIG. 17 , each of the vertices of first hexagonal outer panel portion  1600  are aligned with and joined to each of the vertices of first hexagonal inner panel portion  1610  and the panel portions are joined along the perimeter of their respective peripheral edges between the vertices. With this configuration, the smaller size of first hexagonal inner panel portion  1610  causes first hexagonal outer panel portion  1600  to bulge outward causing the exterior surface to have a substantially convex surface. 
       FIG. 17  also illustrates an exemplary embodiment of forming a first pentagonal panel segment  1702  by joining first pentagonal outer panel portion  1620  and first pentagonal inner panel portion  1630  along their respective peripheral edges. In this embodiment, each of the vertices of first pentagonal outer panel portion  1620  are aligned with and joined to each of the vertices of first pentagonal inner panel portion  1630  and the panel portions are joined along the perimeter of their respective peripheral edges between the vertices. With this configuration, the smaller size of first pentagonal inner panel portion  1630  causes first pentagonal outer panel portion  1620  to bulge outward causing the exterior surface to have a substantially convex surface. 
     In an exemplary embodiment, the peripheral edges of the respective panel portions of first hexagonal panel segment  1700  and/or first pentagonal panel segment  1702  may be joined using adhesive or any other suitable attachment mechanism described above in regards to first panel segment  600 . 
     In some embodiments, a cover for an inflatable game ball in the form of a soccer ball may be formed by attaching multiple hexagonal shaped panel segments and pentagonal shaped panel segments in a predetermined truncated icosahedron shape. In various embodiments, the arrangement of individual panel segments of different shapes used to form the cover may vary depending on the type of soccer ball being constructed. For example, a cover for a 32-panel soccer ball may include 20 hexagonal shaped panel segments and 12 pentagonal shaped panel segments. Other cover panel arrangements that may be used to construct a soccer ball include an 18-panel and a 26-panel construction. In still other embodiments, different cover panel arrangements for inflatable game balls using a larger or smaller number of panel segments may be provided. 
     Referring now to  FIG. 18 , a soccer ball  1800  may be formed with a cover having a 32-panel construction. In an exemplary embodiment, one or more of the panel segments forming the cover of soccer ball  1800  may include first hexagonal panel segment  1700  and/or first pentagonal panel segment  1702  made using the process described herein. In this embodiment, first pentagonal panel segment  1702  may be surrounded by and attached to five substantially similar panel segments as first hexagonal panel segment  1700 . Similar groupings of substantially similar panel segments may extend around soccer ball  1800  to form the cover. Each of the panel segments may be attached to adjacent panel segments using stitching, bonding, adhesive, or any other suitable attachment mechanisms described herein or known in the art. With this arrangement, the outer panel portions of each panel segment forming the cover of soccer ball  1800  are subject to less variation in size caused by differences in stretch properties of the outer layer material used to make the outer panel portions. As a result, the amount of variation between individual soccer balls produced within the tolerances of the dimensions required by different leagues or agencies may be limited or minimized. 
     Additionally, in some embodiments, panel segments using the process described herein may be combined with panel segments made using conventional construction processes. With this arrangement, some portions of an inflatable game ball may be provided with tighter construction tolerances and less variation in stretch properties, while other portions including the convention panel segments may be allowed to vary and stretch in a conventional manner. 
     While various embodiments of the disclosure 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 disclosure. Accordingly, the disclosure 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.