Patent Document

BACKGROUND 
   1. Technical Field 
   This invention relates to inflation needles, and more particularly to needles for inflating sports balls and the like. 
   2. Background Information 
   Throughout this application, various publications, patents and published patent applications are referred to by an identifying citation. The disclosures of the publications, patents and published patent applications referenced in this application are hereby incorporated by reference into the present disclosure. 
   Traditional inflation needles for sports balls and like include relatively long, thin hollow metallic probes configured to be axially inserted into the bung of the ball. While these needles may be reasonably effective in many applications, they have been found to be relatively delicate and subject to bending and breakage during use. Such breakage is at best inconvenient, requiring a user to remove the broken pieces from a pump and/or ball, and to begin the inflation process again with a new inflation needle. Such breakage also runs the risk, however, of the severed probe tip becoming lodged within the bung, where it may become difficult if not impossible to remove without damaging the ball. 
   Examples of various inflation needles include that disclosed by Gaines in U.S. Pat. No. 6,923,222, which is a conventional inflating needle of the type commonly employed for inflating sports balls. 
   Morris et al. (U.S. Pat. No. 4,043,356) disclose an inflator probe for filling gas containers, which includes a one-piece body molded from a plastic material and providing a cylindrical externally threaded end piece for attachment to a pump followed by an enlarged-diameter shoulder having finger grips and an elongated tapered nozzle extending therefrom. 
   Blair (U.S. Pat. No. 615,670) discloses a multiple component inflating nipple which includes a tapered shank threadably engaged with a nut captured at an end of a cup. The relatively narrow cup axially supports the shank as the nut is rotated to effect insertion. 
   None of these references disclose or address the problem of needle breakage during use. A need, therefore, exists for an improved inflation needle which addresses drawbacks of the prior art. 
   SUMMARY 
   In one aspect of the invention, an inflation needle, includes a tubular body having an attachment end configured for engagement with an air pump. The body fairs into a tubular probe extending along a longitudinal axis from a proximal end to a distal end which is configured for being inserted into an object to be inflated. A concavo-convex base extends radially outward from the body and towards the distal end, and terminates at a periphery spaced radially from the tubular probe, and which is configured to engage the object upon insertion of the probe therein. The periphery defines a transverse dimension of the base, and the probe defines an axial dimension extending from the periphery to the distal end, and a ratio of the transverse dimension to the axial dimension is at least 0.5:1. The inflation needle is a unitary, molded polymeric component. 
   In another aspect of the invention, an inflation needle includes a tubular body having an attachment end configured to be engaged with a fluid supply. The body fairs into a tubular probe extending along a longitudinal axis from a proximal end to a distal end configured for being inserted into an object to be inflated. A concavo-convex base extends radially outward from the body and towards the distal end, terminating at a periphery spaced radially from the tubular probe, the base being configured to engage the object upon insertion of the probe therein. The inflation needle is a unitary, molded polymeric component. 
   In still another aspect of the invention, a method for manufacturing an inflation needle includes providing a tubular body having an attachment end configured to be engaged with a fluid supply, and fairing the body into a tubular probe extending along a longitudinal axis from a proximal end to a distal end configured for being inserted into an object to be inflated. A base is extended radially outward from the body and towards the distal end, terminating at a periphery spaced radially from the tubular probe, so that the base has a substantially concave surface facing the distal end, the base being configured to engage the object upon insertion of the probe therein. The inflation needle is molded as a unitary, polymeric component. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The above and other features and advantages of this invention will be more readily apparent from a reading of the following detailed description of various aspects of the invention taken in conjunction with the accompanying drawings, in which: 
       FIG. 1  is a perspective view of an embodiment of the subject invention; 
       FIG. 2  is a perspective view of an alternate embodiment of the subject invention; 
       FIG. 3  is a perspective view of another alternate embodiment of the subject invention; and 
       FIG. 4  is an elevational view of still another embodiment of the subject invention shown in engagement with a portion of an object to be inflated. 
   

   DETAILED DESCRIPTION 
   In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized. It is also to be understood that structural, procedural and system changes may be made without departing from the spirit and scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims and their equivalents. For clarity of exposition, like features shown in the accompanying drawings shall be indicated with like reference numerals and similar features as shown in alternate embodiments in the drawings shall be indicated with similar reference numerals. 
   Where used in this disclosure, the term “axial” when used in connection with an element described herein, refers to a direction substantially parallel to the insertion direction of the needle. The term “transverse” refers to a direction other than (e.g., substantially orthogonal) to the axial direction. The term “fluid” is used in its conventional sense, to refer to gases such as air, and liquids. 
   It was discovered by the instant inventors that prior art inflation needles tended to break due to the relatively high transverse (shear) forces to which the needles were often subjected during use. It was found that it is often difficult to insert the probe and inflate the ball without accidentally pushing the probe sideways, i.e., transversely to the insertion direction. Conditions of the sports field and use by children tend to be particularly conducive to rough handling of the needle. Also, the rounded surfaces of various sports balls make them particularly likely to roll as pressure is applied to the needle to insert and/or maintain secure engagement with a pump, which may serve to apply a transverse, bending moment to the needle. This bending moment, due to the needle&#39;s relatively small transverse dimension and thin tubular walls, has been found to often result in fractures or breaks therein. It was hypothesized that by providing a means to oppose these transverse forces, the needle would be better able to resist such breakage. 
   Embodiments of the present invention include an inflation needle having a probe and a flange or base which would engage the curved surface of a ball, etc., upon insertion of the probe. In the event the probe is pushed in a sideways direction during insertion or inflation, this movement would be opposed by engagement of the flange with the ball. In addition, the compression force associated with continued pressure applied to the needle, such as to maintain connection with the pump during inflation, may be distributed over the wider cross sectional area of the flange, rather than being concentrated on the narrower probe. In particular embodiments, the base is substantially concavo-convex, with a generally concave surface facing the ball, to enable its periphery to engage the rounded surface of the ball. In particular embodiments, the concavo-convex base is cylindrical or frusto-conical. 
   Referring now the Figures, embodiments of the invention will be described in greater detail. Turning to  FIG. 1 , an inflation needle  100  has a concavo-convex base  104  which, upon full insertion of the probe  108 , engages the surface of the object to be inflated, such as the spherical surface of a sports ball. The skilled artisan, upon review of the instant disclosure, will recognize that the substantially concave inner configuration of base  104  enables it to engage a substantially convex surface (e.g., of a ball), at a point spaced transversely from probe  108 . Indeed, as best shown in  FIG. 4 , the concavo-convex structure of the various base configurations enables them to engage the convex surface  150  of a ball, along their peripheries  114 . This relatively widely spaced engagement provides a relatively large moment arm to counteract any bending moment inadvertently applied by the user as discussed above. 
   An attachment end  102  is configured to be coupled to a pump or other supply of air (e.g., compressor or other compressed gas supply) or other fluid suitable to the particular application. In the embodiment shown, the attachment end  102  is threaded or knurled to facilitate attachment to a fluid supply. Those skilled in the art will recognize that attachment end  102  may be provided with nominally any other type of fitting to facilitate fluid connection. 
   The base  104  may include a scored edge  106 , allowing an improved grip for a user grasping the base  104  during handling, such as while coupling the attachment end  102  to the fluid supply and/or inserting the needle into the ball. The needle  100  is tubular/hollow and includes at least one hole  110  near the distal (insertion) end, to allow the fluid to flow therethrough in a conventional manner. In alternate embodiments, the insertion end of the probe  108  may comprise two or more holes  110 . 
   In particular embodiments, the needle  100  is fabricated from a moldable polymeric material, such as a high density or reinforced plastic. Selection of particular polymeric materials may enable the probe  108  thereof to be more resilient and less susceptible to breakage than a traditional metallic needle. Examples of suitable materials include but are not limited to polyamide (NYLON® DuPont), thermoplastics, or engineered resins, such as sulfone polymers, polypropylene, polyethylene, polyesters, polycarbonate, polyurethane, acrylonitrile-butediene-styrene (ABS), styrene-acrylonitile (SAN), or fiberglass. Fabrication of the needle from these polymers, particularly when using conventional high-volume approaches such as injection molding, may reduce manufacturing costs and/or complexities relative to traditional multiple-component metallic needles. 
   In an alternate embodiment, the inflation needle may include a stem, such as to provide improved grip for a user. Referring to  FIG. 2 , needle  200  includes a stem  212  disposed between base  104  and attachment end  102 . A stem may be used with bases of nominally any desired shape, such as the frusto-conical base  304  of  FIG. 3 . As shown, stem  212  optionally has grooved, striated sides to allow better gripping during use. As also shown, in particular embodiments, the exterior transverse dimension of stem  212  is approximately equal to the exterior dimension of attachment end  102 , as will be discussed in greater detail hereinbelow with respect to  FIG. 4 . 
   As shown in  FIG. 3 , needle  300  includes a concavo-convex base  304  which is substantially frusto-conical. Base  304  is also shown with an optional scored edge  306  for improved grip by the user. 
   Turning now to  FIG. 4 , embodiments of the present invention may be provided with a wide range of dimensions suitable for any of various inflation applications. For many applications, base  104 ,  304 ,  404  is provided with an exterior transverse dimension T, and probe  108  is provided with an axial dimension A 4 , configured to provide a ratio T:A 4  which is at least 0.5:1, and which may be as high as about 1:1 or more in some embodiments. This ratio provides a transverse dimension T that is substantially larger than the transverse dimension T 3  of probe  108 . As discussed hereinabove, this relatively large dimension T, in combination with the inner concave configuration of the base, engages a surface  150  of an object to be inflated at a relatively large distance from probe  108 . As discussed hereinabove, this large distance provides a relatively large moment arm that effectively opposes typical transverse forces applied to probe  108  during insertion and/or use. As also discussed, this relatively large distance also defines a relatively large cross-sectional area that tends to distribute any axial forces that may continue to be applied upon full insertion of the needle. 
   Although concavo-convex base  104 , has been shown and described as being substantially semi-spherical, and base  304  has been shown as being frusto-conical, substantially any concavo-convex shape may be used, such as a cylindrical, box, dome shape, a series of spaced fingers, or other more complex concavo-convex configurations. Nominally any concavo-convex configuration may be used, which provides a concave surface facing the distal (insertion) end, to facilitate with a curved surface of the object to be inflated. In addition, while peripheries  114  are shown and described as being substantially circular, it should be understood that the various concavo-convex base configurations described herein may effectively form peripheries of nominally any configuration, including various polygonal or spoked configurations that may or may not provide an uninterrupted or continuous engagement with surface  150 . Rather, nominally any periphery configuration may be used, as long as it is capable of engaging a convex surface  150  at least two, and preferably at least three locations spaced radially about the axis of probe  108  upon insertion thereof. For example, a concavo-convex base may be fabricated as a series of fingers  304 ′ spaced about probe  108 , as shown in phantom in  FIG. 3 , which may engage the surface of a ball at their tips. 
   As also shown, representative embodiments of probe  108  are provided with an axial dimension A 4  which may be within a range of about 30 mm to about 50 mm, and in particular embodiments, 35 mm to about 45 mm. Base  104 ,  304 ,  404 , etc., has an axial dimension A 3  which may be within a range of about 2 mm to about 6 mm, and in particular embodiments, about 3 mm to about 5 mm. Attachment end  102  and optional stem  212  ( FIG. 2 ) have axial dimensions A 1  and A 2  respectively, which are each within a range of about 5 mm to about 10 mm, or about 7 mm to about 9 mm in some embodiments. These embodiments may thus be provided with an overall axial dimension A within a range of about 40 mm to about 80 mm, and in particular embodiments, about 55 mm to about 65 mm. 
   Attachment end  102  and optional stem  212  are provided with transverse dimensions T 1  and T 2  which may both be within a range of about 5 mm to about 10 mm in some embodiments, and within a range of about 8-9 mm in others. Base  104 ,  304 ,  404 , etc., has an exterior transverse dimension T which may be within a range of about 15 mm to about 25 mm in various embodiments, and in particular embodiments, within a range of about 21 mm to about 23 mm. Exterior transverse dimension T 3  of probe  108  may be within a range of about 1 mm to about 4 mm in various embodiments, or about 2 mm to about 3 mm in other embodiments. 
   The following illustrative example is intended to demonstrate certain aspects of the present invention. It is to be understood that this example should not be construed as limiting. 
   Example 
   An inflation needle substantially as shown and described in  FIG. 4  is injection molded as a single, unitary component, from a polymeric material. The needle includes a base  404  having an exterior transverse dimension T of about 22 mm, and a probe  108  having an axial dimension A 4  of about 40 mm, for a ratio T:A 4  of about 0.5:1. 
   Attachment end  102  and stem  212  both have axial dimensions A 1  and A 2 , respectively, of about 8 mm. Base  404  has an axial dimension A 3  of about 4 mm, to provide a total length A of about 60 mm. 
   Attachment end  102  and stem  212  have respective transverse dimensions T 1  and T 2  of about 8-9 mm. Probe  108  has an exterior transverse dimension T 3  of about 2 mm. 
   In the preceding specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense.

Technology Category: 4