Automated ball manufacturing method

Abstract

A method of manufacturing a sports article, preferably a ball, comprising the following steps (preferably in this order): a) providing a mold having an inner profile; b) providing a shell material to form an outer shell of the final product; c) arranging the shell material in the mould; d) closing the mould and, after closing, adding a foamed polymer into the closed mould.

Description

Technical Field

[0001] This invention relates to a method for manufacturing moving parts using molds. Background Technology

[0002] Manufacturing sporting goods (such as balls) using molds often comes at a cost: typically, the foam core is surrounded by a panel that needs to be glued to the core, a manufacturing step that is difficult to automate and requires the use of glue.

[0003] CN102814050A relates to a method and apparatus for manufacturing a PU foam toy ball. The manufacturing method includes: printing colored text on a transfer film set on a flat surface; after preliminary deformation, placing the transfer film into a mold; adding mixed PU foam material into the mold; and after molding, peeling off the substrate layer and release layer of the transfer film to obtain a high-elasticity PU foam toy ball.

[0004] US4,980,107A discloses an in-mold coating and a method for producing polyurethane-based molded articles using the coating. The coating is demoldable, requires no external release agent, and can be recoated after demolding without additional surface treatment.

[0005] The downsides are that the mold cannot be closed before adding the foaming material, and the intermediate parts of the final product require several demoldings. Additionally, external heating of the mold is necessary, which increases manufacturing costs. Therefore, an improved method is needed to automate the manufacturing of sporting goods such as balls.

[0006] In view of the above, there is a need for an improved method for manufacturing sporting goods, preferably one that is automated. Therefore, the object of the present invention is to overcome some or all of the aforementioned deficiencies of the prior art. Summary of the Invention

[0007] The above-mentioned objectives are achieved, at least in part, through embodiments of this application. Preferred embodiments are provided in these embodiments, and those skilled in the art will find clues to other suitable aspects of the invention throughout the entire disclosure of this application.

[0008] One aspect of the invention relates to a method of manufacturing a sporting article (preferably a ball), the method comprising the steps (preferably in this order): a) providing a mold having an inner contour; b) providing a shell material to form the outer shell of the final product; c) arranging the shell material within the mold; d) closing the mold, and after closing, adding a foamed polymer to the closed mold.

[0009] This method can be used to manufacture, for example, soccer balls with a durable and uniform shell. The inner contour of the mold ensures that the shell material is shaped to the precise form required for optimal performance. By injecting the foamed polymer into a closed mold, the product (such as a ball) gains improved cushioning and resilience, thereby increasing its usability and lifespan. This manufacturing technology offers advantages such as consistent product quality and efficient mass production capabilities, making it ideal for sporting goods manufacturers.

[0010] This method can be further improved when the shell material in step (b) comprises: i) at least one polymer sheet, preferably overlapping polymer sheets, to avoid visible and / or perceptible seams on the surface of the article; or ii) a pre-formed polymer bag; or iii) an in-mold coating (IMC).

[0011] The use of overlapping polymer sheets is particularly beneficial when forming articles (such as balls), where a seamless shell is important for both aesthetic appeal and performance, thereby minimizing irregularities that could affect the article's trajectory or bounce. Alternatively, using pre-formed polymer bags may be ideal for other articles, providing uniformity and speed in production. Liquid in-mold coating may be advantageous for other complex shapes or designs, where the coating produces a durable, seamless outer layer that enhances the article's aerodynamics and overall performance. Each material choice offers specific advantages, such as improved surface integrity, a streamlined manufacturing process, and enhanced product performance, making them suitable for a wide range of sporting equipment applications.

[0012] This method can be improved when the method includes, or follows, step (c): applying a pressure differential to the mold, such that the polymer sheet and / or bag conforms to the inner contour of the mold.

[0013] Applying a pressure differential ensures that the overlapping polymer sheets or polymer bags adhere tightly to every bend and / or corner of the mold's inner surface. This adhesion is important for maintaining the shape of the article and ensuring its final surface is smooth and uniform, which is necessary for consistent performance. The advantage of this method is that it improves molding accuracy, resulting in the production of motion articles with excellent quality and reproducibility.

[0014] This method can be further improved when it includes, in or after step (c), a preforming step to adapt the polymer sheet and / or bag to the inner contour of the mold, wherein the preforming step includes applying heat and / or applying a displacer. This displacer can be implemented as a pusher or actuating device that uses force to preform the polymer sheet and / or bag to adjust them to the desired contour. Applying heat can be beneficial, for example, by reducing the stiffness of the material to be formed and by helping to introduce thermal stress into the material, thereby enabling the material to produce the desired deformation.

[0015] This method can be further improved when the mold includes at least two hemispherical mold mating parts to form a complete sphere.

[0016] Spherical mold designs can be used to manufacture spherical balls, such as soccer balls or basketballs. For example, pairing two hemispherical mold components allows for precise control over the final shape of the ball, ensuring symmetry and balance, which are important for the ball's performance in use. The advantages of using this particular mold design include: increased precision in forming the spherical shape of the ball, easier assembly and disassembly of the mold components, and efficient mass production capabilities. This mold structure facilitates the uniform distribution of material—such as overlapping polymer sheets or polymer bags—within the mold cavity, contributing to a high-quality finish and consistent performance of the final product. Furthermore, more than two mold components can be used, which can be beneficial in allowing for balls comprising multiple different layers.

[0017] Further improvements are achieved when the shell material used in step (b) is selected from one or a combination of the following: thermoplastic polyurethane (TPU), low-density polyethylene (LDPE), polyethylene terephthalate (PET), and other suitable polymers including thermoplastics, thermoplastic elastomers, and / or elastomers.

[0018] TPU is particularly advantageous for producing sports equipment—especially balls—because it is known for its high abrasion resistance and robust mechanical properties, ensuring the products can withstand frequent and intense use. LDPE is beneficial for lighter sports equipment, where low density and a soft texture are advantageous. PET, due to its high strength and impact resistance, can be used for more rigid applications. The use of elastomers is also possible if the recoil force of a particular elastomer does not lead to undesirable deformation in the desired form. This can be achieved, for example, by selecting materials with low recoil force or using materials with thinner layers. The ability to select or combine these polymers allows manufacturers to customize the properties of sports equipment to meet the specific requirements of different sports, thereby optimizing performance and enhancing user satisfaction. Each material choice affects not only product performance but also its manufacturing process, environmental impact, and overall marketability.

[0019] Further improvements are achieved when the foaming polymer used in step (d) is selected from one or a combination of the following: polyurethane (PU), thermoplastic polyurethane (TPU), ethylene-vinyl acetate copolymer (EVA), polystyrene (PS), polyvinyl chloride (PVC), polypropylene (PP), polyether block amide (PEBA), and / or other suitable foaming polymers.

[0020] Using PU or TPU as the foaming polymer is particularly advantageous for ball manufacturing, as TPU is valued for its elasticity, a property that ensures the ball can withstand repeated impacts and maintain its shape over time. The expansion properties of TPU and similar foaming polymers also ensure that the inner contours of the mold are completely filled, resulting in a uniformly dense product without air pockets or weak points. The choice of TPU or other suitable foaming polymers allows for a high degree of customization—in terms of the density, flexibility, and feel of the final product—which is important for different types of sporting goods, such as those tailored to specific competition conditions and rules.

[0021] Further improvements are obtained when step (d) involves adding the foaming polymer via one or a combination of the following methods: casting, injection, spraying, and / or blowing.

[0022] Injection molding can be effective because it allows for precise control of the amount of polymer entering the mold, ensuring a consistent density throughout the sporting article. This consistency is crucial for maintaining the shape of the sporting article and optimizing its performance during use. Spraying or blow molding can be advantageous for producing lighter sporting articles, where a more uniform, lower-density polymer distribution may be desired. The versatility of these technologies provides manufacturers with the flexibility to tailor the application of the foamed polymer to the specific requirements of different sporting items, enhancing the functional properties of the product while ensuring high production efficiency.

[0023] The addition of the foaming polymer in step (d) can also be achieved by one or a combination of the following: rinsing with beads followed by melting the beads; and / or adding a block of material followed by expanding the block by applying a vacuum and / or gas. The method is further improved when the mold includes a trimming device (preferably an integrated cutting ring) configured for trimming the shell.

[0024] The included integrated cutting ring precisely trims excess material from the outer shell, resulting in a smooth and uniform surface, which is important for consistent performance and, for example, aerodynamics during the use of sporting goods. This fine trimming enhances the overall aesthetics of the finished product. One advantage of integrating this cutting mechanism directly into the mold is that it streamlines the manufacturing process, reduces the need for additional finishing steps, thereby increasing production efficiency and lowering labor costs. This integrated approach ensures a high-quality finish on sporting goods, meeting industry standards for smoothness and uniformity.

[0025] The method is further improved when it includes a step of trimming excess shell material from the molded moving article. This trimming can be performed outside of, for example, an integrated trimming device, or as a trimming step only.

[0026] This finishing process is particularly advantageous in the production of balls, where precision in the surface texture and symmetry is essential for their performance. Trimming excess shell material ensures that each ball is uniform in size and weight. The benefits of including this finishing step are multiple, including enhanced aesthetic appeal and improved performance characteristics. This process not only improves the final appearance of the product but also contributes to the overall reliability and performance of sporting goods, making them suitable for competitive use.

[0027] The method is further improved when any overlapping polymer sheets are further processed after step (d).

[0028] This further processing may involve gluing or pressing to more firmly bond overlapping areas. This is particularly advantageous in the production of high-quality balls, where the surface needs to be as uniform as possible to ensure consistent performance. Gluing helps fuse the sheets together, while pressing flattens any unevenness, ensuring the ball's exterior is free of irregularities that could affect, for example, its trajectory during use. The advantage of this additional processing step is that it contributes to the production of more durable and reliable sporting goods. By ensuring good integration of the overlapping sheets, this method reduces the likelihood of seams cracking or deteriorating over time, which is important for maintaining the quality of the product throughout regular use. This process not only improves the aesthetic appeal and performance of sporting goods, but it also increases their lifespan and durability, thus meeting the high standards required, for example, in competitive sports environments.

[0029] The method is further improved when further processing includes one or a combination of welding and / or gluing to ensure the seamlessness and integrity of the housing.

[0030] The application of welding or gluing can be beneficial for the production of products intended for use in demanding environments, particularly for balls. In this case, welding can bond overlapping polymer sheets to create a single, uniform layer that is highly resistant to cracking or breakage under high impact conditions. Alternatively, using strong adhesives to bond the sheets together can also provide a durable bond that maintains the integrity of the product's surface, ensuring it remains smooth and consistent in texture, which is important for predictable handling and performance during use. The advantages of introducing welding or gluing into the processing of overlapping polymer sheets are significant. It not only ensures the seamlessness and aesthetic quality of sporting goods but also significantly improves their durability and lifespan. This processing step facilitates the production of sporting equipment that can withstand harsh use in competitive environments, thus providing manufacturers with a reliable method to produce high-quality, durable sporting products.

[0031] To further improve the method, the foaming polymer is added from the top side of the mold.

[0032] Introducing the foaming polymer from the top allows for controlled and gradual filling of the mold, which is crucial for achieving a consistent density, for example, throughout the entire ball. This consistent density is essential to ensure, for example, that the ball exhibits uniform bounce characteristics and maintains its spherical shape during activity. The advantages of adding the foaming polymer from the top of the mold include better control over material flow and distribution, which helps eliminate air pockets and ensures that every part of the mold is fully filled. This method enhances the structural integrity of sporting goods and improves the overall quality of the final product. This precision in the manufacturing process is necessary to meet demanding standards—for example, those required in professional sports equipment—thus ensuring the high performance and durability of the manufactured sporting goods.

[0033] In different embodiments, the addition of the foaming polymer is not achieved from the top of the mold.

[0034] Adding the foaming polymer from one side of the mold, rather than the other, allows for controlled addition—independent of gravity. The foaming polymer can be introduced from either side of the mold, provided that trapped air can escape through appropriate measures (e.g., ventilation channels).

[0035] The method is further improved when it excludes the intermediate demolding step.

[0036] This aspect of the process can be particularly advantageous where maintaining precise dimensions and structural integrity is critical. By holding, for example, a ball within the mold throughout the curing and bonding stages, this method ensures the ball retains its precise spherical shape and uniform material properties, essential for consistent movement characteristics such as trajectory, rotation, and / or maneuverability. The absence of an intermediate demolding step improves production efficiency and quality control. It reduces handling time and risk associated with moving and resetting partially cured products, thereby minimizing defects and variations in the final product. This lean approach not only optimizes the manufacturing process but also improves the overall reliability and performance of finished sporting goods, making them ideal for both professional and recreational applications.

[0037] To further improve the method, the method does not include a heating step in or after step (d).

[0038] This method can be particularly advantageous because the absence of a heating step means that the materials used—such as certain types of foamed polymers and shell materials—must naturally bond and cure at ambient temperature or slightly elevated temperatures, caused, for example, by the exothermic nature of chemical reactions within the foamed polymer. This is important for maintaining, for example, the texture and elasticity of a sphere, which are crucial for consistent performance and durability. The advantages of not introducing a heating step include reduced manufacturing complexity and lower energy costs, making the process more environmentally friendly and cost-effective. Furthermore, avoiding heating prevents the degradation or warping of heat-sensitive materials, thus ensuring that the final product maintains high quality and performance standards. Therefore, this method enhances the sustainability and efficiency of the manufacturing process.

[0039] To further improve the method, the mold contains aluminum.

[0040] Using aluminum molds is advantageous because aluminum's high thermal conductivity helps distribute heat or any exothermic reaction evenly within the mold, ensuring uniform curing of the internal foamed polymer. This uniform curing contributes to consistent bounce and durability, for example, in balls. Advantages of using aluminum molds include enhanced heat management during manufacturing, which improves the quality of sporting goods by preventing hot spots and uneven curing. Additionally, aluminum's durability and lightweight properties make the molds easier to handle and maintain, reducing downtime and increasing production efficiency. In conclusion, choosing aluminum as the mold material supports high-volume, consistent manufacturing processes, meeting the industrial needs for high-quality, reliable sporting goods.

[0041] To further improve the method, the mold may contain steel and / or polymer, preferably 3D printed polymer.

[0042] When high thermal conductivity is required, using steel in molds can be beneficial while still maintaining enhanced structural robustness. The advantage of using polymers lies in the versatility of materials available for producing molds, allowing for material selection that is tailored to specific product requirements. In the case of using 3D-printed polymers in molds, the possible mold profiles that can be created in this way increase. Attached Figure Description

[0043] Preferred embodiments of the present disclosure are disclosed below with reference to the accompanying drawings.

[0044] Figure 1 The mold used in the method according to the present invention is shown in a perspective view.

[0045] Figure 2 It is shown in a three-dimensional diagram. Figure 1 The polymer sheet inside the mold.

[0046] Figure 3The closed shape is shown in a 3D diagram. Figure 2 The mold.

[0047] Figure 4 A 3D diagram illustrates the process of adding the foaming polymer. Figure 3 The mold.

[0048] Figure 5 The cured product is shown in a 3D view. Figure 4 The opened mold.

[0049] Figure 6A Figure C shows different balls produced using the method according to the invention.

[0050] Figure 7 The mold, including the trimming device, is shown in a side view.

[0051] Figure 8 It shows Figure 7 Sporting products manufactured in molds.

[0052] Figure 9 The mold used for overlapping polymer sheets is shown in a side view.

[0053] Figure 10 It shows Figure 9 The ball is manufactured in a mold. Detailed Implementation

[0054] The following sections provide a detailed description of the invention, with reference to the accompanying drawings for clarity. These descriptions are illustrative only and are not intended to limit the scope of the invention. The same reference numerals in the drawings and text denote the same parts. The illustrations may not reflect actual dimensions or proportions; for better understanding and visual convenience, their dimensions, proportions, and elements may be depicted with enhancements.

[0055] Figure 1 An open mold 100 is shown, which includes two hemispherical mold mating parts, namely a first hemispherical mating part 110 and a second hemispherical mating part 112.

[0056] This mold construction can be used for the production of spheres. When the two hemispherical mold pieces 110 and 112 are joined together, a spherical cavity is created, which is necessary to form a sphere with precise dimensions and symmetry. This is crucial for ensuring consistent ball performance during use, such as in terms of bounce and aerodynamics. The advantage of this mold design lies in its simplicity and effectiveness in producing high-quality spherical sports products. Clearly dividing the mold into two halves not only facilitates the manufacturing process but also aids in mold maintenance and cleaning, thereby improving the overall efficiency and lifespan of the manufacturing equipment.

[0057] Figure 2 The arrangement in Figure 1 The shell material within the mold 100. Here, the shell material is constructed from a first polymer sheet 210 and a second polymer sheet 212. The first polymer sheet 210 is disposed on the first hemispherical mating member 110, and the second polymer sheet 212 is disposed on the second hemispherical mating member 112.

[0058] Once the mold is closed and the manufacturing process is complete, this arrangement is crucial for achieving a seamless shell. Two polymer sheets 210 and 212 serve as fundamental elements of the sphere's outer surface, and their precise placement ensures that the seams between the sheets are perfectly aligned when the mold-matching parts are placed together, minimizing any visible or tangible discontinuities on the sphere's surface. The advantages of arranging each polymer sheet in its respective mold half before mold closure include enhanced control over the thickness and uniformity of the shell material, which directly impacts the quality and performance of the final product. This method also allows for customization of material properties in each half, potentially using polymer sheets of different types or thicknesses to enhance specific performance characteristics of the sporting article.

[0059] exist Figure 3 In the middle, locking is achieved by closing the first hemispherical mating member 110 and the second hemispherical mating member 112. Figure 2 The mold 100 is configured such that the first polymer sheet 210 and the second polymer sheet 212 face each other. In this way, an insertion channel 300 is formed on the upper side of the mold.

[0060] A pressure differential, such as a vacuum, is then applied inside the mold, causing the first polymer sheet 210 to adhere to the contour of the first hemispherical mating member 110, and the second polymer sheet 212 to adhere to the contour of the second hemispherical mating member 112. This adhesion is important for obtaining a seamless and uniform shell with optimal contact, which enhances the structural integrity and aesthetic quality of the final product. This setup helps ensure that the shell of the sphere is smooth and free of any defects that could affect the sphere's performance. The application of vacuum helps remove any air pockets between the polymer sheet and the mold surface, ensuring that the sheet precisely conforms to the spherical shape required by the mold.

[0061] exist Figure 4 In the middle, foamed polymers—through Figure 3 The insertion channel 300 of the mold 100 (hidden) is introduced into the volume between the first polymer sheet 210 and the second polymer sheet 212.

[0062] Foam and polymer sheets are interconnected to form a monolithic sphere. This process is essential for creating the core of the sphere—surrounded by the polymer sheet forming the outer shell. The foamed polymer not only fills the spaces to provide structure but also provides mechanical properties such as cushioning and resilience, which are important for the sphere's performance during use. The interconnection between the foamed polymer and the polymer sheet is crucial because it ensures that the outer shell and core are integrated into a single, durable structure, necessary for maintaining shape integrity and providing the required impact response. Furthermore, the use of intercalation channels to introduce the foamed polymer ensures controlled and uniform distribution of the material, minimizing air pockets and inconsistencies within the sphere.

[0063] Figure 5 The image shows the opening after the foamed polymer has cured and bonded to the first polymer sheet 210 and the second polymer sheet 212. Figure 4 The mold. The ball 10 can be demolded. The interior of the ball 10 is formed of foamed polymer, and the outer shell is formed of a first polymer sheet 210 and a second polymer sheet 212.

[0064] The core of the sphere 10, formed from a foamed polymer, provides the necessary cushioning and rebound properties, while the outer shell, made of polymer sheets 210 and 212, provides the smooth and durable surface necessary for handling and long-term use. The entire structure supports the sphere's ability to withstand repeated impacts and maintain its shape and performance over time. The advantages of this manufacturing process are evident in the seamless integration of materials, ensuring the sphere is robust and performs consistently under a variety of usage conditions.

[0065] Figure 6A Two exemplary spheres manufactured according to the method of the present invention are shown. The first sphere 610 is formed of a medium-flexibility polymer sheet, and excess material 614 has not yet been trimmed. The second sphere 612 is formed of the same medium-flexibility polymer sheet and has been trimmed.

[0066] The second ball 612 shows a ball in its final, ready-to-use state, with a clean and smooth surface, free of any excess material—which might have been present after the initial molding process. Trimming excess material is a crucial step in ensuring the ball meets the required specifications for performance and aesthetic quality. Without trimming, the presence of excess material can adversely alter important mechanical and aerodynamic properties.

[0067] Figure 6B Two exemplary spheres manufactured according to the method of the present invention are depicted. The first sphere 620 is formed from a very flexible foil-like polymer sheet and has been trimmed. The second sphere 622 is formed from the same very flexible foil-like polymer sheet, and excess material 624 has not yet been trimmed.

[0068] The use of highly flexible foil-like polymer sheets allows for precise control over surface texture and hardness, properties that are important for the ball's aerodynamic and durability performance. As shown in ball 620, the finishing process is crucial for ensuring consistent finished product performance by eliminating any irregularities or protrusions that could affect the ball's trajectory and behavior during use.

[0069] Figure 6C An exemplary sphere manufactured according to the method of the present invention is shown. The sphere 630 is formed of a rigid polymer sheet, and excess material 634 has not yet been trimmed.

[0070] Using rigid polymer sheets can be important to provide—the necessary stiffness and weight distribution that some balls may require. The rigidity of the polymer sheet ensures durability and maintains—the structural integrity needed—to withstand repeated impacts experienced during use.

[0071] Figure 7 A mold including a trimming device is depicted in a side view. The mold includes first and second spherical mating parts 710, 712 with vacuum channels 702. First and second polymer sheets 810, 812 are precisely fitted around the contours of the first and second spherical mating parts 710, 712. An integral cutting ring 704 is arranged on the outer region of the spherical contour of the second spherical mating part 712.

[0072] These vacuum channels 702 facilitate the attachment of polymer sheets 810, 812 to the contours of the mold: the first polymer sheet 810 precisely fits around the contour of the first spherical mating member 710, and the second polymer sheet 812 similarly fits around the contour of the second spherical mating member 712. This precise fit ensures that the polymer sheets conform tightly to the shape of the mold, thereby minimizing any gaps or irregularities. An integral cutting ring 704 is used to trim any excess material from the polymer sheets 810, 812, ensuring clean and precise edges on the finished product. This integral cutting ring simplifies the trimming process by directly attaching it to the mold, eliminating the need for additional trimming steps after demolding. The integral cutting ring is configured for trimming the outer shell and can be a heated blade to further facilitate trimming.

[0073] Figure 8 It shows Figure 7 The ball 80 is a moving article manufactured in a mold. The ball 80 includes interconnected polymer sheets 810, 812, which have excess shell material 834 to be trimmed.

[0074] Interconnected polymer sheets 810 and 812 form the outer shell of sphere 80. Excess shell material 834 extends beyond the intended shape of the sphere and needs to be trimmed. This excess material is located around the seam where polymer sheets 810 and 812 overlap or meet.

[0075] Figure 9 A mold for overlapping polymer sheets is shown in a side view. The mold 900 includes first and second spherical mating members 910, 912 that hold the first and second polymer sheets 1010, 1012. The polymer sheets 1010, 1012 are arranged such that they overlap when the mold is closed to avoid visible and / or perceptible seams on the surface of the article.

[0076] This overlapping construction ensures that the seams between the sheets are invisible or imperceptible on the surface of the final sporting article, thus providing a smooth and continuous outer layer. The overlapping of polymer sheets is a key feature for enhancing the aesthetic and functional quality of sporting articles—by minimizing surface irregularities and ensuring a more durable and cohesive structure.

[0077] Figure 10 It shows Figure 9 The sphere 1000 is manufactured in a mold. The sphere 1000 is formed from interconnected and overlapping polymer sheets 1010, 1012. The polymer sheets 1010, 1012 are joined in the overlapping region 1004 by further processing using an ultrasonic welding apparatus 1002. Further processing may include ultrasonic welding or other welding or gluing to ensure the seamlessness and integrity of the shell.

[0078] Polymer sheets are precisely joined in overlapping areas 1004 to ensure a seamless and durable bond. The joining process in overlapping areas 1004 is achieved using an ultrasonic welding apparatus 1002. Ultrasonic welding uses high-frequency ultrasonic vibrations to create a solid-state weld between the polymer sheets without requiring additional adhesives or external heat. This method provides a strong and seamless bond, enhancing the structural integrity and surface smoothness of the sphere.

[0079] Figure label:

[0080] 10, 80, 610, 612, 620, 622, 630, 1000: Ball

[0081] 100, 700, 900: Molds

[0082] 110, 710, 910: First spherical mating parts

[0083] 112, 712, 912: Second spherical mating parts

[0084] 210, 810, 1010: First polymer sheet

[0085] 212, 812, 1012: Second polymer sheet

[0086] 300: Insert Channel

[0087] 614, 624, 634, 834: Redundant materials

[0088] 702: Vacuum Channel

[0089] 704: One-piece cutting ring

[0090] 1002: Ultrasonic welding equipment

[0091] 1004: Overlapping region

Claims

1. A method for manufacturing a sporting item, preferably a ball, the method comprising the following steps: a) Provide a mold with an inner contour; b) Provide shell material to form the outer casing of the final product; c) Arrange the shell material inside the mold; d) Close the mold and add the foaming polymer into the closed mold after closing.

2. The method according to claim 1, wherein, The shell material in step (b) includes: i) at least one polymer sheet, preferably overlapping polymer sheets, to avoid visible and / or perceptible seams on the surface of the article; or ii) Pre-formed polymer bags; or iii) Liquid in-mold coating (IMC).

3. The method of claim 2, wherein, The method includes, in or after step (c): applying a pressure differential to the mold such that the polymer sheet and / or the bag conforms to the inner contour of the mold.

4. The method according to claim 2 or 3, wherein, The method includes applying a preforming step to adapt the polymer sheet and / or the bag to the inner contour of the mold, wherein the preforming step includes applying heat and / or applying a displacement device.

5. The method according to any one of the preceding claims, wherein, The mold includes at least two hemispherical mold pairs to form a complete sphere.

6. The method according to any one of the preceding claims, wherein, The shell material used in step (b) is selected from one or a combination of the following: thermoplastic polyurethane (TPU), low-density polyethylene (LDPE), polyethylene terephthalate (PET), and other suitable polymers including thermoplastic plastics, thermoplastic elastomers and / or elastomers.

7. The method according to any one of the preceding claims, wherein, The foaming polymer used in step (d) is selected from one or a combination of the following: polyurethane (PU), thermoplastic polyurethane (TPU), ethylene-vinyl acetate copolymer (EVA), polystyrene (PS), polyvinyl chloride (PVC), polypropylene (PP), polyether block amide (PEBA) and / or other suitable foaming polymers.

8. The method according to any one of the preceding claims, wherein, In step (d), the foaming polymer is added by one or a combination of the following: casting, injection, spraying, and / or blowing.

9. The method according to any one of the preceding claims, wherein, The addition of the foaming polymer in step (d) is carried out by one or a combination of the following: rinsing with beads and then melting the beads; and / or adding a block of material and then expanding the block of material by applying a vacuum and / or gas.

10. The method according to any one of the preceding claims, wherein, The mold includes a trimming device, preferably an integral cutting ring, which is configured to trim the outer shell.

11. The method according to any one of the preceding claims, the method further comprising the step of trimming excess shell material from the molded motion article.

12. The method according to any one of claims 2 to 11, wherein, After step (d), any overlapping polymer sheets are subject to further processing.

13. The method according to claim 12, wherein, The further processing includes one or a combination of welding and / or gluing to ensure the seamlessness and integrity of the housing.

14. The method according to any one of the preceding claims, wherein, The foaming polymer is added from the top side of the mold.

15. The method according to any one of claims 1 to 13, wherein, The addition of the foaming polymer is not achieved from the top side of the mold.

16. The method according to any one of the preceding claims, wherein, The method does not include an intermediate demolding step.

17. The method according to any one of the preceding claims, wherein, The method does not include a heating step in or after step (d).

18. The method according to any one of the preceding claims, wherein, The mold contains aluminum.

19. The method according to any one of the preceding claims, wherein, The mold comprises steel and / or polymer, preferably a 3D-printed polymer.

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