Patent Description:
A variety of inflatable sports balls, such as soccer balls, conventionally exhibit a layered structure that includes a casing, an intermediate structure, and a bladder. The casing forms an exterior portion of the sports ball and is generally formed from a plurality of durable and wear-resistant panels joined together along abutting edge areas (e.g., with stitching, adhesives, or bonding), i.e., via a seam. Designs such as decorative elements and holistic textural patterns may be applied to the exterior surface of the casing.

An intermediate structure forms a middle portion of the sports ball and is positioned between the casing and the bladder. Among other purposes, the intermediate structure may provide a softened feel to the sports ball, impart energy return, and restrict expansion of the bladder.

<CIT> describes an ellipsoidal athletic ball comprising a valve equipped ellipsoidal bladder, a cover, and a fibrous structure intermediate the bladder and the cover including a reinforcing tape in the form of a loop having its ends interconnected and lying in line with the major axis of the ball and also including a separate set of fabric strips applied to the bladder surface at each side of the reinforcing tape and disposed obliquely to said reinforcing tape, said strips at each side of the reinforcing tape being in progressively overlapping relation to cover the surface of the bladder and with the ends of each set of strips having lapping relationship with the ends of the other set of strips at points along the length of said reinforcing tape, all of the strips in each set having one end connected to the reinforcing tape at one point in the length of the ball and the other end connected to said reinforcing tape at another point in the length of said ball, and with the obliqueness of one set of fabric strips with respect to said reinforcing tape being opposite to that of the other set.

<CIT> describes an inflatable athletic ball comprising a spherical valve-equipped bladder, a layer of fabric pieces applied directly to said bladder, a layer of thread turns applied to said fabric layer, an outer layer of fabric applied to the thread turns comprising fabric strips of narrow width substantially encircling the ball disposed on great circles at <NUM>° to each other and also comprising a plurality of shorter fabric strips, acting as filler strips closing in spaces between. the first strips and disposed on great circles, and a cover applied to said last-named layer.

<CIT> describes soccer balls comprised of a generally spherically shaped center portion or core prepared from a piece(s) of material, multistrand yarn at least partially covering this center portion, tape at least partially covering the yarn covered center portion, a synthetic cloth cover. The cover is preferably formed of two cloth pieces which have patterns imprinted thereon by, e.g., silk screening, designed so that, when the cover is secured over the wrapped center portion, the ball has the appearance of a conventional soccer ball.

<CIT> describes an inflatable sports ball. The sports ball includes an interior bladder and a cover disposed about the interior bladder. The cover may include an outer substrate and an intermediate structure. The cover may further include an outer substrate surface, defined by the outer substrate, and a feature surface radially spaced apart from the outer substrate surface. Together the outer substrate surface and the feature surface cooperate to define an exterior surface of the cover. A mechanoluminescent material may be embedded in a portion of the cover. The mechanoluminescent material may be disposed at only one of the outer substrate surface and the feature surface, such that it is positioned to form a predetermined design on the cover. The mechanoluminescent material emits visible light in response to an externally-applied stress, such that the predetermined design illuminates when an external stress or mechanical stimulus is exerted upon the cover.

The claimed invention is defined by the independent claim, while specific embodiments form the subject of the dependent claims.

An inflatable sports ball is provided. The inflatable sports ball comprises a bladder, an outer cover layer, and an intermediate structure. The bladder may define an exterior bladder surface, a bladder circumference, and a valve opening configured to receive a valve. The intermediate structure is disposed between the outer cover layer and the bladder. The intermediate structure comprises a restriction structure.

The restriction structure is configured to restrict the expansion of and maintains the shape of the bladder. The restriction structure is formed in a non-planar configuration and shaped to conform with the exterior bladder surface. More particularly, the restriction structure further comprises a plurality of overlapping strips wrapped about the bladder circumference. In this way, the restriction structure comprises a uniform number of radially-stacked layers of the overlapping strips over a substantial entirety of the exterior bladder surface.

While the present disclosure may be described with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure. Those having ordinary skill in the art will recognize that terms such as "above," "below," "upward," "downward," etc., are used descriptively of the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Any numerical designations, such as "first" or "second" are illustrative only and are not intended to limit the scope of the disclosure in any way.

The terms "comprising," "including," and "having" are inclusive and therefore specify the presence of stated features, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, or components.

The terms "a," "an," "the," "at least one," and "one or more" are used interchangeably to indicate that at least one of the items is present.

The following discussion and accompanying figures disclose various sports ball configurations and methods relating to the manufacturing of the sport balls. Although the sports ball is depicted as a soccer ball in the associated figures, concepts associated with the configurations and methods may be applied to various types of inflatable sport balls, such as basketballs, footballs (for either American football or rugby), volleyballs, water polo balls, etc..

Referring to the drawings, wherein like reference numerals refer to like components throughout the several views, an inflatable sports ball <NUM> is provided. In a general sense, the sports ball <NUM> of the present disclosure includes a casing <NUM> disposed about an interior bladder <NUM>. The casing <NUM> includes an outer cover layer <NUM> and an intermediate structure <NUM> disposed between the outer cover layer <NUM> and the interior bladder <NUM>. The intermediate structure <NUM> includes a restriction structure <NUM> configured to restrict the expansion of and maintain the shape of the interior bladder <NUM>, when the bladder <NUM> is inflated to a predetermined internal pressure. The restriction structure <NUM> comprises a plurality of overlapping strips <NUM> wrapped about a circumference <NUM> of the bladder <NUM>. In this way, the restriction structure <NUM> comprises a uniform number of radially-stacked layers of the overlapping strips <NUM> over a substantial entirety of the exterior bladder surface <NUM> between the exterior bladder surface <NUM> and the outer cover layer <NUM>.

The plurality of overlapping strips <NUM> is a beneficial configuration for the restriction structure <NUM>, because such a configuration creates a uniform number of radially-stacked layers and/or a uniform thickness of the restriction structure <NUM> across a substantial entirety of the exterior bladder surface <NUM>. Such a configuration of the restriction structure <NUM> also eliminates a need for an adhesive binder to secure the respective strips <NUM> in place on the bladder <NUM>. Such consistency in the number of radially-stacked layers of the overlapping strips <NUM> across an entirety of the exterior bladder surface <NUM>, as well as the absence of a heavy and/or bulky resin binder, promotes improved consistency in rebound characteristics, improved balance (reduced wobble), as well as improved touch properties of the sports ball <NUM>.

Such a configuration of the restriction structure <NUM> also allows for consistency in manufacturing, as well as optimization of the dimensions, e.g., size, weight, and sphericity of the sports ball <NUM>, which is particularly beneficial when the sports ball <NUM> is embodied as an inflatable soccer ball, as depicted in <FIG>, as high level, pro quality soccer balls shall be manufactured to at least the specifications set forth by Federation Internationale de Football Association (FIFA) for Size <NUM> FIFA Quality Pro level soccer balls. Sports balls <NUM> governed by the Size <NUM> FIFA Quality Pro level specifications are required to embody a circumference of from <NUM> millimeters to about <NUM> millimeters, a weight of from <NUM> grams to <NUM> grams, a sphericity max percentage of <NUM>%, and a rebound height of from <NUM> centimeters to <NUM> centimeters at <NUM> degrees Celsius. Further, a restriction structure <NUM> formed via the particular overlapping strips <NUM> of <FIG> of the present disclosure, allows for efficient manufacturing of the restriction structure <NUM> while mitigating waste of the material, which comprises the respective overlapping strips <NUM> thereof.

As shown in <FIG>, the sports ball <NUM> may be an inflatable sports ball <NUM> such as a soccer ball or the like. A sports ball <NUM> having the general configuration of a soccer ball is depicted in <FIG>. As shown in <FIG>, <FIG>, and <FIG>, the sports ball <NUM> may have a layered structure including an interior <NUM>, an intermediate structure <NUM>, and an outer cover layer <NUM>. The outer cover layer <NUM> forms an exterior portion of the sports ball <NUM>. The interior <NUM> forms an interior portion of the sports ball <NUM>.

The interior may be a bladder <NUM> (<FIG>, <FIG>) having an exterior bladder surface <NUM>. The bladder <NUM> may be formed from a variety of elastomeric or otherwise stretchable materials and may be further capable of being inflated to a predetermined internal pressure. More particularly, the bladder <NUM> may be formed of a Thermoplastic Polyurethane (TPU) material or a rubber material. In order to facilitate inflation (i.e., fill the interior with pressurized air) of the bladder <NUM> to the predetermined internal pressure, the bladder <NUM> defines a valved opening <NUM> that houses a valve <NUM> and extends through the bladder <NUM>, the outer cover layer <NUM>, and the intermediate structure <NUM>, thereby allowing access to the valve <NUM> from an exterior surface <NUM> of the sports ball <NUM>. Upon inflation, the bladder <NUM> is pressurized and the pressurization induces the exterior bladder surface <NUM> and the exterior surface <NUM> of the sports ball <NUM> to be non-planar and substantially-spherical surfaces, as the sports ball <NUM> takes on a substantially-spherical shape. As shown in <FIG> and <FIG>, the ball <NUM> may have an interior center <NUM> and a central axis A that runs through the interior center <NUM>. The valve <NUM> and the valved opening <NUM> may be positioned on the central axis A.

In some examples, a counterweight <NUM> (<FIG>) may be disposed on the central axis A opposite the valve <NUM> on the ball <NUM> to better balance the resultant sports ball <NUM>. In this way, the counterweight <NUM> is positioned diametrically opposite the inflation valve <NUM> to counterbalance the weight of the inflation valve <NUM> and position the center of gravity of the ball <NUM>, when inflated to the predetermined internal pressure, at the geometric center <NUM> of the sphere. The counterweight <NUM> may be a textile patch, a foam patch, or the like.

The casing <NUM> is disposed about the interior bladder <NUM> and forms an exterior portion of the sports ball <NUM>, which further defines the exterior surface <NUM>. As shown in <FIG> and <FIG>, the casing <NUM> may comprise a layered structure including an outer cover layer <NUM> and an intermediate structure <NUM> located interior to the outer cover layer <NUM> between the outer cover layer <NUM> and the bladder <NUM>. Said another way, the intermediate structure <NUM> is disposed between the outer cover layer <NUM> and the bladder <NUM>.

The intermediate structure <NUM> forms a middle portion of the sports ball <NUM> and is positioned between the outer cover layer <NUM> and the bladder <NUM>. Among other purposes, the intermediate structure <NUM> may provide a softened feel to the sport ball <NUM>, impart energy return, and restrict expansion of the bladder <NUM>. In some configurations, the intermediate structure <NUM> or portions of the intermediate structure <NUM> may be bonded, joined, or otherwise incorporated into the outer cover layer <NUM> as a backing material. In other configurations, the intermediate structure <NUM> or portions of the intermediate structure <NUM> may be bonded, joined, or otherwise incorporated into the interior <NUM>.

The intermediate structure <NUM> may include a restriction structure <NUM> and a plurality of intermediate layers 26a, 26b. The restriction structure <NUM> is disposed in contact with the bladder exterior surface <NUM>. The plurality of intermediate layers 26a, 26b are disposed between the outer cover layer <NUM> and the restriction structure <NUM>, and may be bonded, joined, or otherwise incorporated into the outer cover layer <NUM> as a backing material. The counterweight <NUM> may be disposed upon the restriction structure <NUM> between the restriction structure <NUM> and the intermediate layers 26a, 26b.

The intermediate layers 26a, 26b may include a first intermediate layer 26a and a second intermediate layer 26b. The first intermediate layer 26a is disposed between the second intermediate layer 26b and the outer cover layer <NUM>. The second intermediate layer 26b is disposed between the first intermediate layer 26a and the restriction structure <NUM>. The intermediate layers 26a, 26b may be comprised of a suitable textile material or foam material. Examples of suitable polymer foam materials include, but are not limited to, polyurethane, ethylvinylacetate, and the like. Examples of suitable textile materials include, but are not limited to, a woven or knit textile formed from polyester, cotton, nylon, rayon, silk, spandex, or a variety of other materials. A textile material may also include multiple materials, such as a polyester and cotton blend.

The intermediate layers 26a, 26b provide a softened feel to the sports ball <NUM> and provide insulation of the bladder <NUM> to minimize sound generated by striking the air-filled and pressurized bladder <NUM>. In one example configuration, the first intermediate layer 26a may comprise a thermoplastic foam material, and more particularly, a Thermoplastic Polyurethane (TPU) foam material. In such an example, the second intermediate cover layer 26b may comprise a winding layer, wherein a textile yard, thread, or filament is repeatedly wound about the restriction structure <NUM> to form a mesh that covers substantially all of the restriction structure <NUM>. In this way, the second intermediate layer 26b allows for optimization of the size and weight dimensions of the ball <NUM>, while imparting improved rebound characteristics. In other embodiments, each of the intermediate layers 26a, 26b may comprise foam materials.

The restriction structure <NUM> may have a variety of configurations and/or functional purposes, including, but not limited to, restricting expansion of the bladder <NUM>, imparting energy return, and improving consistency in the size, weight, balance, and rebound properties of the sports ball <NUM>. Upon pressurization to a predetermined internal pressure, the bladder <NUM> induces the sports ball <NUM> to take on a non-planar and substantially spherical shape. More particularly, pressure within the bladder <NUM> causes the exterior bladder surface <NUM> to place an outward force upon the restriction structure <NUM>, which is disposed in contact with the bladder exterior surface <NUM>. In turn, the restriction structure <NUM> places an outward force upon the casing <NUM>, particularly the second intermediate layer 26b. Said another way, bladder <NUM> places an outward force upon restriction structure <NUM>, but the reduced stretch characteristics of restriction structure <NUM> effectively mitigate the outward force from inducing significant tension in casing <NUM>. As such, the restriction structure <NUM> restrains pressure from the bladder <NUM>, while permitting outward forces to induce a non-planar and substantially-spherical shape in the casing <NUM>, thereby imparting a substantially- spherical shape to the sports ball <NUM>.

As such, in general, the restriction structure <NUM> may be formed from materials with a limited degree of stretch in order to limit the expansion of bladder <NUM> and also limit tension in casing <NUM>, or, alternatively, restriction structures <NUM> formed from a mildly-stretchable material may be paired with a material with a limited degree of stretch in order to limit the expansion of the bladder <NUM>, while also improving rebound and resilience characteristics of the sports ball <NUM>. Accordingly, the construction of the restriction structure <NUM> may vary significantly to include a variety of configurations and materials.

As examples, conventional restriction structures may be formed from (a) thread, yarn, or filament that is repeatedly wound around bladder <NUM> in various directions to form a mesh that covers substantially all of a bladder <NUM>, (b) a plurality of generally flat or planar strips that are impregnated with latex and placed in an overlapping configuration around bladder <NUM>, or (c) a substantially seamless textile. In utilizing a conventional restriction structure such as (a)-(c) detailed herein above, there is generally a large amount of textile material as well as latex or resin binder needed to provide the necessary restriction of the bladder <NUM>, which causes difficulties in controlling the dimensions, i.e., the size, weight, and sphericity of the resultant sports ball <NUM>, as well as less predictability in consistency of the flight characteristics, rebound and resilience characteristics, and touch properties of the ball <NUM>.

More particularly, the amount of material utilized for a conventional restriction structure <NUM> to achieve the desired sound characteristics, improved resilience, and improved rebound properties often produces a ball <NUM> that is heavier or larger in diameter and/or circumference than desired or required by specifications such as the specifications set forth by Federation Internationale de Football Association (FIFA) for Size <NUM> FIFA Quality Pro level soccer balls. Application of conventional restriction structures to the bladder <NUM> in the manufacturing process also produces inconsistencies in the dimensions, i.e., the size, weight, and sphericity of the resultant sports ball <NUM>. These inconsistencies can be solved via the present disclosure.

As shown in <FIG>, <FIG> the restriction structure <NUM> of the present disclosure is composed of a plurality of overlapping strips <NUM>, such that the restriction structure <NUM> comprises a uniform number of radially-stacked layers of the overlapping strips <NUM> or a uniform thickness over a substantial entirety of the exterior bladder surface <NUM>. Further, the restriction structure <NUM> is formed in a non-planar configuration and is shaped to conform with exterior bladder surface <NUM> (<FIG>), when the bladder <NUM> is inflated.

In one example, the overlapping strips <NUM> may comprise a textile material. The textile material may be a woven, knit, or similarly formed textile. The textile material may further incorporate an elastomeric element, to refine the stretch characteristics of the textile material. The textile material may further incorporate a thermoplastic component or be impregnated with a thermoplastic component, such that the overlapping strips <NUM> or layers thereof may be welded together. Accordingly, examples of suitable textile materials include, but are not limited to, a muslin material, a canvas material, a woven or knit textile formed from wool, polyester, cotton, nylon, rayon, silk, spandex, or a variety of other materials. A textile material may also include multiple materials, such as a polyester and cotton blend. Examples of suitable thermoplastic components may include, but are not limited to, polyurethane, polyethylene, polypropylene, polyvinyl chloride, polystyrene, acrylic, nylon, and the like.

In another example, the overlapping strips <NUM> may comprise an elastomeric material. The elastomeric material may be a rubber material, a Thermoplastic Polyurethane (TPU) material, or another suitable elastomeric material. In such an example, wherein the overlapping strips <NUM> comprise an elastomeric material, the overall resilience and rebound properties of the resultant sports ball <NUM> may be improved. However, in such an example, the elastomeric material alone may not have the requisite limited stretch properties to sufficiently restrain expansion of the bladder <NUM>. As such, in an example wherein the overlapping strips <NUM> comprise an elastomeric material, the second intermediate layer 26b of the intermediate structure <NUM> may be comprised of a winding layer. In such an example, the winding layer comprises at least one of a textile yard, thread, or filament that is repeatedly wound about the overlapping strips <NUM> of the restriction structure <NUM> to form a mesh that covers substantially all of the restriction structure <NUM>. In this way, the winding layer provides that the additional limited stretch properties to the intermediate structure <NUM> to sufficiently restrain expansion of the bladder <NUM>, while the elastomeric material of the restriction structure <NUM> allows for the improved rebound and resilience properties of the resultant sports ball <NUM>. The winding layer also provides for the ability to improve or optimize the size, weight, and sphericity of the resultant sports ball <NUM> during the manufacturing process.

As illustrated in <FIG> and <FIG>, the plurality of overlapping strips <NUM> may be arranged prior to assembly on the bladder <NUM>, to define a nexus void <NUM>. In this way, the nexus void <NUM> is disposed on the central axis A, such that the nexus void <NUM> is aligned with the valve <NUM> and the valved opening <NUM> and the valve <NUM> is disposed in the nexus void <NUM>. As shown in <FIG>, once the plurality of strips <NUM> is disposed on and wrapped about the bladder <NUM>, a uniform number of radially-stacked layers of overlapping strips <NUM> within the restriction structure <NUM> are disposed over a substantial entirety of the exterior bladder surface <NUM>. For example, the restriction structure <NUM> may comprise a first layer 22a of overlapping strips <NUM> and a second layer 22b of overlapping strips <NUM> over the entirety of the exterior bladder surface <NUM>.

Each strip <NUM> has a first end <NUM>, a second end <NUM>, a first edge <NUM>, and a second edge <NUM>. The first end <NUM> is positioned opposite the second end <NUM>, such that a length <NUM> of the respective strip <NUM> is measured from the first end <NUM> to the second end <NUM>. The first edge <NUM> is further positioned opposite the second edge <NUM>, such that a width <NUM> of the respective strip <NUM> is measured from the first edge <NUM> to the second edge <NUM>. Further each of the first edge <NUM> and the second edge <NUM> extend from the first end <NUM> to the second end <NUM> of each respective strip <NUM>. Each strip <NUM> may further define an aspect ratio of length <NUM> to width <NUM>. The aspect ratio of length <NUM> to width <NUM> may be from about <NUM>:<NUM> to about <NUM>:<NUM>.

In one example embodiment, the aspect ratio of length <NUM> to width <NUM> of the respective strip <NUM> may be from about <NUM>:<NUM> to about <NUM>:<NUM>. In such an example embodiment, which is partially illustrated in <FIG>, the plurality of strips <NUM> may comprise a plurality of overlapping patches disposed about the entirety of the exterior bladder surface <NUM>. In such an example, the first layer 22a is welded to the second layer 22b across the entirety of the exterior bladder surface <NUM> and throughout the restriction structure <NUM>. As utilized and further defined herein, the term "welding" or variants thereof (such as "thermal bonding") is defined as a technique for securing two elements to one another that involves a softening or melting of a polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled. Similarly, the term "weld" or variants thereof (e.g., "thermal bond") is defined as the bond, link, or structure that joins two elements through a process that involves a softening or melting of a polymer material within at least one of the elements such that the materials of the elements are secured to each other when cooled.

In another example embodiment, as illustrated in <FIG>, <FIG>, the aspect ratio of length <NUM> to width <NUM> of the respective strip <NUM> may be greater than about <NUM>:<NUM> and more particularly about <NUM>:<NUM>. Said another way, the width <NUM> of the respective strip <NUM> may be quantified as from about <NUM>/<NUM>th to about <NUM>/<NUM>th of the length <NUM> or from about <NUM>% to about <NUM>% of the length <NUM> of the respective strip <NUM>. Such length <NUM> and width <NUM> dimensions for the strips <NUM>, namely, an aspect ratio of length <NUM> to width <NUM> of from about <NUM>:<NUM> to about <NUM>:<NUM>, provide for a mitigation of waste material in the manufacture of the restriction structure <NUM>.

In such an example, the length <NUM> of the respective strip <NUM> may be substantially the same as the measurement of the bladder circumference <NUM>, when the sports ball <NUM> is inflated to the predetermined internal pressure. As such, the width <NUM> of the respective strip <NUM> may be quantified as from about <NUM>/<NUM>th to about <NUM>/<NUM>th of the measurement of the bladder circumference <NUM>, when the sports ball <NUM> is inflated to the predetermined internal pressure and/or from about <NUM>% to about <NUM>% of the bladder circumference <NUM>, when the sports ball <NUM> is fully inflated to the predetermined internal pressure.

According to the invention, and as illustrated in <FIG>, the plurality of overlapping strips <NUM> is further defined as a plurality of overlapping and interwoven strips <NUM> (<FIG>). In such an example, the restriction structure <NUM> again comprises a uniform number of radially-stacked layers of the overlapping and interwoven strips <NUM> over a substantial entirety of the exterior bladder surface <NUM>, for example, two layers, namely, a first layer 22a and a second layer 22b. In such an example, the first layer 22a is interwoven with and welded to the second layer 22b.

In one example, wherein the plurality of overlapping strips <NUM> are further defined as a plurality of overlapping and interwoven strips <NUM>, each strip <NUM> may be formed in a linear configuration, such that each of the first edge <NUM> and the second edge <NUM> are linear. While being linear in configuration, the first edge <NUM> and the second edge <NUM> remain substantially parallel along the length <NUM> of the respective strip <NUM>.

In another example, wherein the plurality of overlapping strips <NUM> are further defined as a plurality of overlapping and interwoven strips <NUM>, each strip <NUM> may be formed in a wave-like configuration as illustrated by example in <FIG>. Referring to <FIG>, the first edge <NUM> and second edge <NUM> define a wave-like configuration comprising a plurality of crests and a plurality of depressions. In such an example, the first edge <NUM> is non-linear and the second edge <NUM> is non-linear.

The first edge <NUM> may define a first plurality of crests <NUM>, a first plurality of depressions <NUM>, and a first edge equilibrium <NUM>. Each crest <NUM> of the first plurality of crests extends to a crest terminus <NUM> that is spaced apart from the first edge equilibrium <NUM> in a first direction D1 by a first edge crest height 70a. Each depression <NUM> of the first plurality of depressions extends to a depression terminus <NUM> that is spaced apart from the first edge equilibrium <NUM> in a second direction D2, which is opposite the first direction D1, by a first edge depression depth 72a.

The second edge <NUM> may define a second plurality of crests <NUM>, a second plurality of depressions <NUM>, and a second edge equilibrium <NUM>. Each crest <NUM> of the second plurality of crests extends to a crest terminus <NUM> that is spaced apart from the second edge equilibrium <NUM> in the first direction D1 by a second edge crest height 70b. Each depression <NUM> of the second plurality of depressions extends to a depression terminus <NUM> that is spaced apart from the second edge equilibrium <NUM> in the second direction D2 by a second edge depression depth 72b.

Further, the first plurality of crests <NUM> and the first plurality of depressions <NUM> may further comprise an alternating and repeating series of crests <NUM> and depressions <NUM>, such that the first edge <NUM> takes on a wave-like configuration. In this way, each crest <NUM> is positioned between two depressions <NUM> and each depression <NUM> is positioned between two crests <NUM>. Likewise, the second plurality of crests <NUM> and the second plurality of depressions <NUM> may further comprise an alternating and repeating series of crests <NUM> and depressions <NUM>, such that the second edge <NUM> takes on a wave-like configuration. In this way, each crest <NUM> is positioned between two depressions <NUM> and each depression <NUM> is positioned between two crests <NUM>.

However, while being non-linear in configuration, the first edge <NUM> and the second edge <NUM> remain substantially parallel along the length <NUM> of the respective strip <NUM>. Accordingly, each crest <NUM> of the first plurality of crests is aligned with one of the crests <NUM> of the second plurality of crests and each depression <NUM> of the first plurality of depressions is aligned with one of the depressions <NUM> from the second plurality of depressions.

More particularly, the first edge crest height 70a is substantially the same as the first edge depression depth 72a. The second edge crest height 70b is substantially the same as the second edge depression depth 72b. The first edge crest height 70a is substantially the same as the second edge crest height 70b. The first edge depression depth 72a is substantially the same as the second edge depression depth 72b. Further, the first edge crest height 70a and the first edge depression depth 72a cooperate to define the wave amplitude of the first edge <NUM>. Likewise, the second edge crest height 70b and the second edge depression depth 72b cooperate to define the wave amplitude of the second edge <NUM>.

In one example, as illustrated in <FIG>, the wave amplitude of the first edge <NUM> is from about <NUM>/<NUM>th or <NUM>% of the width <NUM> of the respective strip <NUM> to about <NUM>/<NUM>rd or <NUM>% of the width <NUM> of the respective strip <NUM>. Likewise, the wave amplitude of the second edge <NUM> is from about <NUM>/<NUM>th or <NUM>% of the width <NUM> of the respective strip <NUM> to about <NUM>/<NUM>rd or <NUM>% of the width <NUM> of the respective strip <NUM>. More particularly, in one example, the wave amplitude of each of the first edge <NUM> and the second edge <NUM> is about <NUM>/<NUM>th or about <NUM>% of the width <NUM> of the respective strip <NUM>.

Said another way, the first crest height 70a, the second crest height 70b, the first depression depth 72a, and the second depression depth 72b may quantified as from about <NUM>/<NUM>th or <NUM>% of the width <NUM> of the respective strip <NUM> to about <NUM>/<NUM>th or <NUM>% of the width <NUM> of the respective strip <NUM>. More particularly, the first crest height 70a, the second crest height 70b, the first depression depth 72a, and the second depression depth 72b may be quantified as approximately <NUM>/<NUM>th of or from about <NUM>% to about <NUM>% of the width <NUM> of the respective strip <NUM>, such that the ratio of first crest height 70a to width <NUM> is about <NUM>:<NUM>, the ratio of second crest height 70b to width <NUM> is about <NUM>:<NUM>, the ratio of first depression depth 72a to width <NUM> is about <NUM>:<NUM>, the ratio of second depression depth 72b to width <NUM> is about <NUM>:<NUM>.

In one example embodiment, the plurality of overlapping and interwoven strips <NUM> comprises six overlapping and interwoven strips <NUM>, namely, a first strip 15a, a second strip 15b, a third strip 15c, a fourth strip 15d, a fifth strip 15e, and a sixth strip 15f (<FIG>). In the six-strip example, illustrated in <FIG> and <FIG>, the first strip 15a, the second strip 15b, the third strip 15c, the fourth strip 15d, and the fifth strip 15e are positioned radially about the nexus void <NUM>, such that the nexus void <NUM> is disposed between the first end <NUM> and the second end <NUM> of each of the respective strips <NUM> (<FIG>). Each of the first strip 15a, the second strip 15b, the third strip 15c, the fourth strip 15d, and the fifth strip 15e are interwoven with each of the other strips <NUM> (<FIG>) and wrapped about the bladder circumference <NUM> (<FIG>).

Once wrapped about the bladder circumference <NUM>, the first end <NUM> of the respective strip <NUM> is positioned adjacent to and in contact with the second end <NUM> of that respective strip <NUM>, such that the first end <NUM> abuts the second end <NUM> thereby forming a restrictor ring about the bladder circumference <NUM>. More particularly, the first end <NUM> of the first strip 15a is positioned adjacent to and in contact with the second end <NUM> of the first strip 15a, the first end <NUM> of the second strip 15b is positioned adjacent to and in contact with the second end <NUM> of the second strip 15b, the first end <NUM> of the third strip 15c is positioned adjacent to and in contact with the second end <NUM> of the third strip 15c, the first end <NUM> of the fourth strip 15d is positioned adjacent to and in contact with the second end <NUM> of the fourth strip 15d, and the first end <NUM> of the fifth strip 15e is positioned adjacent to and in contact with the second end <NUM> of the fifth strip 15e, when the plurality of strips <NUM> of <FIG> are overlapped and interwoven about the bladder circumference <NUM>. The sixth strip 15f is then disposed about the equator of the bladder <NUM> and wrapped about the bladder circumference <NUM>, such that the first end <NUM> of the sixth strip 15f is positioned adjacent to and in contact with the second end <NUM> of the sixth strip 15f.

The first end <NUM> and second end <NUM> of the respective strips <NUM> may be fixed to one another via welding, adhesive binder, stitching, or another suitable coupling mechanism, such that the respective restrictor ring is interwoven with each of the other restrictor rings and secured about the bladder circumference <NUM>.

In some embodiments, the outer cover layer <NUM> may be composed of a variety of suitable materials including leather and/or suitable polymeric materials. In some configurations the outer cover layer <NUM> is composed of a polymeric material, a polymer foam material, or the like. Examples of suitable polymeric materials include, but are not limited to, polyurethane, polyvinylchloride, polyamide, polyester, polypropylene, polyolefin, and/or other materials that are generally durable and wear-resistant. In one example, the outer cover layer <NUM> may be formed of a thermoplastic polyurethane material (TPU).

As shown in <FIG>, and <FIG>, the outer cover layer <NUM> may be generally formed by a plurality of adjoining panels <NUM>, wherein each panel <NUM> has a respective panel surface that defines a portion of the outer cover layer surface <NUM>. The plurality of panels <NUM> may comprise the conventional twelve (<NUM>) panels or any other number of panels <NUM>, for example, four joined panels <NUM> each having nine edges <NUM> and having a generally triangular shape that is formed from three pentagons. Panels <NUM> may also have a variety of other shapes (e.g., triangular, square, rectangular, trapezoidal, round, oval) that combine in a tessellation-type manner to form the outer cover layer <NUM>. Further, panels <NUM> may also exhibit non-regular or non-geometrical shapes. The outer cover layer <NUM> may also exhibit a substantially uniform or unbroken configuration that does not include panels <NUM> joined at abutting edge areas <NUM> via seams <NUM> or may include fewer panels <NUM>.

As shown in <FIG>, <FIG>, <FIG>, and <FIG>, the outer cover layer <NUM> may further define a plurality of surface features <NUM>, <NUM>, <NUM>. The plurality of surface features <NUM>, <NUM>, <NUM> may include a first plurality of indentations <NUM>, a second plurality of indentations <NUM>, and a plurality of protrusions <NUM>. The outer cover layer surface <NUM> may define a plurality of land areas <NUM> disposed between the respective indentations <NUM>, <NUM> and/or protrusions <NUM>. Further, the protrusions <NUM>, the land areas <NUM>, the first plurality of indentations <NUM>, and second plurality of indentations <NUM> may cooperate to define a topographical arrangement across the exterior surface <NUM> of the sports ball <NUM>.

As shown in <FIG>, the first plurality of indentations <NUM> may have a first indentation terminus <NUM> radially-spaced apart from the outer cover layer surface <NUM> in a direction toward the interior bladder <NUM>. Further, each of the first plurality of indentations <NUM> has a first indentation depth <NUM> and a first indentation width <NUM>. The first indentation terminus <NUM> is radially-spaced apart from the outer cover layer surface <NUM> by the first indentation depth <NUM>. In one example, as shown in <FIG>, the first plurality of indentations <NUM> may be defined as a plurality of seams <NUM> configured to couple the plurality of panels <NUM>. In one example, the first plurality of indentations <NUM> are defined as seams, the first indentation width <NUM> is a seam width and the first indentation depth <NUM> is a seam depth.

The respective panels <NUM> may be joined together along abutting edge areas <NUM> (<FIG>) via at least one seam <NUM> (<FIG>). The panels <NUM> may be coupled along the abutting edge areas <NUM> by the seam <NUM> with stitching, bonding, welding, adhesives, or another suitable coupling method.

An example of welded seams <NUM> is disclosed in <CIT> <CIT> generally discloses examples of welded seams, in that welding generally produces a heat affected zone in which the materials of the two joined components are intermingled. This heat affected zone may be considered a "weld" or "thermal bond. " Further, welding may involve (a) the melting or softening of two panels that include polymer materials such that the polymer materials from each panel intermingle with each other (e.g., diffuse across a boundary layer between the polymer materials) and are secured together when cooled, as well as (b) the melting or softening of a polymer material in a first panel such that the polymer material extends into or infiltrates the structure of a second panel (e.g., infiltrates crevices or cavities formed in the second panel or extends around or bonds with filaments or fibers in the second panel) to secure the panels together when cooled. Further, welding may occur when only one panel includes a polymer material or when both panels include polymer materials.

Referring to <FIG> and <FIG>, each of the second plurality of indentations <NUM> may have a second indentation terminus <NUM> radially-spaced apart from the outer cover layer surface <NUM> in a direction toward the interior bladder <NUM>. Further, each of the second plurality of indentations <NUM> has a second indentation depth <NUM> and a second indentation width <NUM>. The second indentation terminus <NUM> is radially-spaced apart from the outer cover layer surface <NUM> by the second indentation depth <NUM>.

The second plurality of indentations <NUM> may be defined as a plurality of channels. In some example embodiments, the channels <NUM> may be spaced apart from the seams <NUM> of the sports ball <NUM> (<FIG>). In other example embodiments, the channels <NUM> may extend to edges <NUM> of the panels <NUM> and, thus, continue across a respective seam <NUM> (<FIG>). More particularly, a channel <NUM> on a first panel and a channel <NUM> on a second panel may be in substantial alignment with one another across a respective seam <NUM>. This may also enable patterns, arrangements, or other designs to be carried across multiple panels, bridging seams <NUM> between the panels <NUM>. Channels <NUM> may impart various advantages to ball <NUM>. For example, channels <NUM> may enhance the aerodynamics of ball <NUM>, provide a greater amount of consistency or control over ball <NUM> during play, e.g., during kicking, dribbling, or passing, improve ball feel, and provide for water channeling.

Channels <NUM> may be formed in the outer cover layer <NUM> via a variety of manufacturing processes including, but not limited to, debossing. Examples of a manufacturing process for forming channels <NUM> are disclosed in <CIT> <CIT> generally discloses a variety of manufacturing processes that may be utilized to form debossed features in panels. In one example, one of the panels is located on a platen. A press plate is positioned above the platen and includes an extension portion having a predetermined shape. The extension portion presses into and heats the areas of panel forming the debossed features. The press plate then moves away from the panel to substantially complete the formation of the debossed feature.

As shown in <FIG>, each channel <NUM> has a channel terminus <NUM> that is radially-spaced apart from the outer cover layer surface <NUM> in a direction toward the interior bladder <NUM>. Further, each channel <NUM> has a channel depth <NUM> and a channel width <NUM>. The channel terminus <NUM> is radially-spaced apart from the outer cover layer surface <NUM> the channel depth <NUM>.

The channels <NUM> are formed in the outer cover layer <NUM> and extend toward the interior bladder <NUM>. The intermediate layers 26a, 26b of the intermediate structure <NUM> are positioned between outer cover layer <NUM> and the restriction structure <NUM>. The outer cover layer <NUM> may be bonded to one of the intermediate layers 26a, 26b at the respective channel <NUM>. More particularly, the outer cover layer <NUM> may be welded directly to the second intermediate layer 26b at the channel terminus <NUM> of the respective channel <NUM> (<FIG> and <FIG>), such that the outer cover layer <NUM> extends through an entirety of the channel depth <NUM> at each of the channels <NUM>.

The channel <NUM> may include an exterior indentation <NUM> and an interior indentation <NUM>. The exterior indentation <NUM> has the terminus <NUM> that is radially-spaced apart from the outer cover layer surface <NUM> by the channel depth <NUM>.

The specific configuration of the channel <NUM> may vary considerably. Referring to <FIG>, the exterior and interior indentations <NUM> and <NUM> may have a generally rounded configuration. As depicted in <FIG> the interior and exterior indentations <NUM> and <NUM> extend to an approximate midpoint of a thickness <NUM> of the panel cross-section. In another configuration, as depicted in <FIG>, the exterior indentation <NUM> extends through more of the thickness <NUM> of panel cross section than the interior indentation <NUM>. In yet another configuration, as depicted in <FIG>, the exterior indentation <NUM> extends through substantially all of the thickness <NUM> of panel cross-section. As also shown in <FIG>, in some embodiments, the second intermediate layer 26b may have a substantially planar configuration opposite the exterior indentation <NUM>. Said another way, in some embodiments, the channel <NUM> may have only an exterior indentation <NUM> and no interior indentation <NUM>.

Referring to <FIG>, indentations <NUM> and <NUM>, as well as the outer cover layer <NUM> and the second intermediate layer 26b, may be spaced from each other, such that a portion of the first intermediate layer 26a extends between indentations <NUM> and <NUM> and between the outer cover layer <NUM> and the second intermediate layer 26b. In this configuration, the outer cover layer <NUM> is bonded to the first intermediate layer 26a at the channel <NUM>. In such an example, the first intermediate layer 26a has a first thickness <NUM> between indentations <NUM> and <NUM> and at the terminus <NUM> of the exterior indentation <NUM>. In the same example, the first intermediate layer 26a has a second thickness <NUM> between the outer cover layer <NUM> and the second intermediate layer 26b, in an area spaced apart from indentations <NUM> and <NUM> and the terminus <NUM> of the exterior indentation <NUM>. As shown in <FIG>, the first thickness <NUM> is less than the second thickness <NUM>.

Alternatively, the channels <NUM> may include an exterior indentation <NUM> and an interior indentation <NUM> that exhibit substantially squared configurations (<FIG>). For example, in some embodiments, the indentations <NUM>, <NUM> may have substantially squared cross-sectional configurations. Such substantially squared cross-sectional configurations may have a more distinct appearance than indentations <NUM>, <NUM> having substantially rounded cross-sectional configurations. In addition, substantially squared indentations <NUM>, <NUM> may also provide performance benefits such as aerodynamics, ball feel, and water channeling.

As shown in <FIG>, the exterior indentation <NUM> and interior indentation <NUM> are two opposing indentations having substantially squared cross-sectional configurations. In <FIG>, the indentations <NUM> and <NUM> extend to an approximate midpoint of the thickness <NUM> of the panel cross-section, such that the terminus <NUM> of the exterior indentation <NUM> is positioned radially inward from the outer cover layer surface <NUM> to the approximate midpoint of the thickness <NUM> of the panel cross-section.

In <FIG>, the exterior indentation <NUM> may extend through substantially the entirety of the thickness <NUM> of the panel cross section. As also shown in <FIG>, in some embodiments, second intermediate layer 26b may have a substantially planar configuration opposite the exterior indentation <NUM>. Said another way, in some embodiments, the channel <NUM> may have only an exterior indentation <NUM> with no interior indentation <NUM>.

As shown in <FIG>, in one example embodiment, the channel <NUM> may include substantially-squared exterior indentation <NUM> having a rounded shoulder portion <NUM>. In some embodiments, a substantially-squared shoulder portion <NUM> may have a minimal radius, as shown in <FIG>. In another example embodiment, a rounded shoulder portion <NUM> having a larger radius may be used, as shown in <FIG>.

Referring to <FIG> and <FIG> the plurality of surface features may further include a plurality of protrusions <NUM>. The plurality of protrusions <NUM> may be disposed upon the outer cover layer surface <NUM>. The protrusions <NUM> may form decorative or aesthetic arrangements or designs upon the outer cover layer surface <NUM> of the sports ball <NUM>, display branding of the sports ball <NUM>, via a logo contained therein, and may further be applied in such an orientation as to optimize grip at the point of contact with the user's hand and/or foot, or to improve aerodynamics during flight.

The protrusions <NUM> may be disposed on a small portion of the outer cover layer surface <NUM>, on a single panel surface, on a select group of panel surfaces, or upon a majority of the outer cover layer surface <NUM> (<FIG>).

Each of the protrusions <NUM> may be formed of a dimensional ink and extend from the outer cover layer surface <NUM>. As shown in <FIG>, each of the plurality of the protrusions <NUM> has a terminus <NUM> that is radially spaced apart from the outer cover layer surface <NUM> by a height <NUM> that is greater than about <NUM> millimeters (mm). In such examples, it is beneficial for the height <NUM> to be at least <NUM> millimeters (mm) and less than <NUM> millimeters (mm) in order to enhance playability of the ball <NUM>. As evaluated via qualitative assessment based on visual observations, protrusions <NUM> having heights <NUM> in the aforementioned range allow for visibility of the respective panel designs and an overall topographical arrangement of the sports ball <NUM>, while also exhibiting a desired grip or contact between a user and/or player's hand or foot and the exterior surface <NUM> of the ball <NUM>, all while still allowing the ball <NUM> to maintain desired aerodynamic and flight characteristics.

As shown in <FIG>, the casing <NUM> may further include an external surface layer <NUM> disposed upon the outer cover layer surface <NUM>. The external surface layer <NUM> may be a film that includes a pigment or a graphic thereon. The external surface layer <NUM> may also be an outer film or clear coat having weather resistant properties. The external surface layer <NUM> may be a polyurethane film or the like. The external surface layer <NUM> may be bonded to the outer cover layer surface <NUM> via a bonding material.

Claim 1:
An inflatable sports ball (<NUM>) comprising:
a bladder (<NUM>) capable of being inflated to a predetermined internal pressure, the bladder (<NUM>) defining an exterior bladder surface (<NUM>);
a casing (<NUM>) disposed about the bladder (<NUM>), the casing (<NUM>) comprising:
an outer cover layer (<NUM>);
an intermediate structure (<NUM>) disposed between the bladder (<NUM>) and the outer cover layer (<NUM>), the intermediate structure (<NUM>) comprising a restriction structure (<NUM>), wherein the restriction structure (<NUM>) comprises a plurality of overlapping strips (<NUM>);
wherein the restriction structure (<NUM>) comprises a uniform number of radially-stacked layers of the overlapping strips (<NUM>) over a substantial entirety of the exterior bladder surface (<NUM>);
wherein the bladder (<NUM>) defines a valve opening configured to receive a valve (<NUM>), the valve (<NUM>) configured to permit selective inflation of the bladder (<NUM>) to the predetermined internal pressure, such that the bladder (<NUM>) defines a bladder circumference (<NUM>), when the bladder (<NUM>) is inflated to the predetermined internal pressure; and
characterized in that
the plurality of overlapping strips (<NUM>) is a plurality of interwoven strips (<NUM>), wherein each strip (<NUM>) is interwoven with each of the other strips (<NUM>) and wrapped about the bladder circumference (<NUM>).