Method for manufacturing a bladder for a ball

Abstract

The invention relates to a method for manufacturing a bladder for a ball, in particular a sports ball, the bladder comprising an electronic module with a protection element, wherein the method comprises the steps of: providing an electronic component on an inner wall of a mold; inserting an unshaped bladder into the mold; and forming the bladder to the inner wall of the mold and simultaneously to the protection element, such that the bladder wall is adapted to form a recess around the electronic component.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a bladder for a ball (particularly a sporting ball), and the ball itself. Specifically, this disclosure relates to integrating an electronic module with protective elements into the bladder during the manufacturing process. Background Technology

[0002] In the field of sports equipment manufacturing, particularly in the production of sports balls, electronic components are often incorporated for various functions such as performance tracking, data collection, and user interaction. Known systems typically involve embedding electronic modules within the ball's structure, which presents several challenges. These challenges include ensuring the protection of electronic components during manufacturing, maintaining the ball's integrity and performance, and achieving seamless integration without compromising the ball's usability or durability.

[0003] Traditional methods of embedding electronics in sports balls typically involve post-manufacturing insertion, where the electronic components are added to the ball after the main manufacturing process is complete. This approach can lead to several problems, such as improper sealing, potential damage to the electronics during use, and difficulty in achieving a uniform ball surface. Furthermore, post-manufacturing insertion complicates the assembly process, increases production costs, and results in inconsistent ball performance due to added weight and altered balance.

[0004] Another approach involves embedding electronics during the initial manufacturing stage, which offers better integration but also presents significant challenges. The electronic components must be protected from the high temperatures and pressures typically involved in ball manufacturing processes such as molding and curing. Without adequate protection, the components may be damaged, leading to malfunctions or shortened lifespan. Furthermore, ensuring that the electronic components are securely fixed within the ball structure without compromising the ball's elasticity and performance is a complex task.

[0005] Despite substantial progress in the manufacture of sporting balls, there is still a need for improved methods to allow for the efficient and reliable integration of electronic components. These methods should ensure the protection of electronics during manufacturing, maintain the ball's performance characteristics, and provide a cost-effective and scalable solution for mass production. Therefore, one technical problem of this invention is to provide a method for manufacturing a sporting ball—with integrated electronic components—that at least partially overcomes the shortcomings of known systems. Summary of the Invention

[0006] One object of the present invention is to provide a method for overcoming the shortcomings of one or more known methods.

[0007] A first aspect of the invention provides a method for manufacturing a bladder for a ball, particularly a sports ball, the bladder including an electronic module with a protective element, wherein the method includes the steps of: providing the electronic component on an inner wall of a mold; inserting an unformed bladder into the mold; and forming the bladder onto the inner wall of the mold and simultaneously onto the protective element, such that the bladder wall is adapted to form a recess around the electronic component.

[0008] This subject describes a method for manufacturing a bladder, particularly for sports balls, which includes an electronic module protected by a protective element. The method includes the following steps: First, the electronic components are provided on the inner wall of the mold. This means placing the electronic modules in specific locations within the mold.

[0009] Next, the unformed bladder is inserted into the mold. This refers to placing the unformed bladder material into the mold where the electronic module has already been placed.

[0010] Third, the bladder is formed onto the inner wall of the mold and simultaneously onto the protective element. This step involves shaping the bladder material to conform to the inner surface of the mold and also forming it around the protective element. As a result, the bladder wall is adapted to create a recess—around the electronic component. This recess ensures that the electronic module is securely housed within the bladder, providing protection and stability.

[0011] The terminology used in this regard is as follows: The term "bladder" as used in this article refers to the inflatable part of a ball; As used in this article, "electronic module" can refer to a component that may include sensors or other electronic devices; The term "protective element" as used in this article refers to a feature designed to protect electronic modules; The "mold" used in this article refers to the form used to shape the bladder; The term "bulb wall" used in this article refers to the outer surface of the bulb. The “pocket” used in this article refers to the space formed inside the bulb wall that houses the electronic modules.

[0012] The advantages of this method include: ensuring that the electronic module is securely integrated into the bladder of the ball, providing protection for the electronic components, and maintaining the structural integrity of the ball. This method allows for the efficient and precise manufacture of sport balls—with embedded electronics—enhancing their functionality and durability.

[0013] In some embodiments, electronic components may be arranged on the outside of the bladder wall and fixed inside the cavity after the bladder is formed.

[0014] Here, the electronic components are positioned on the outer side of the bladder wall and secured within a recess formed around them. This feature introduces a new aspect to the manufacturing process by ensuring the electronic components are securely housed within the designated recess, which is created simultaneously with the bladder's formation. This arrangement provides a protective enclosure for the electronic components, potentially enhancing their durability and functionality by shielding them from environmental factors that could affect their performance. The recess, as a structural feature, not only houses the electronic components but also ensures their stability and protection during the ball's use. By being secured within the recess, the electronic components are less likely to shift or fall out, which could otherwise lead to malfunction or damage.

[0015] In some embodiments, after the step of forming the bulb, the shape of the recess can be adapted to conform to the shape of the electronic component.

[0016] This implementation introduces a novel feature where, after the steps of forming the bladder onto the inner wall of the mold and simultaneously onto the protective element, the shape of the recess formed around the electronic component is specifically adapted to conform to the shape of the electronic component. This adaptation ensures that the bladder wall precisely conforms to the contour of the electronic component, resulting in a close and secure fit. The specific mechanism of communication between the components here involves the interaction between the bladder material and the electronic component during the molding process. By ensuring that the shape of the recess matches the shape of the electronic component, this method enhances the protection and stability of the electronic component within the bladder. This feature offers several advantages, such as reducing the likelihood of movement or displacement of the electronic component within the bladder, which could otherwise lead to potential damage or malfunction. Furthermore, the precise fit helps maintain the overall structural integrity of the bladder and the ball, ensuring that the electronic component remains securely embedded within the bladder during use. This is particularly important for sport balls, which are subjected to significant physical stress and impact during play.

[0017] In some embodiments, the step of forming the bulb is performed by using heat and / or outward-pointing force, and wherein a protective element is adapted to protect the electronic module from the heat and / or outward-pointing force used in the step of forming the bulb.

[0018] This embodiment introduces a specific mechanism for the step of forming the bladder onto the inner wall of the mold and simultaneously onto the protective element. This step is achieved through the use of heat and / or outward-pointing forces. The embodiment also specifies that the protective element is adapted to protect the electronic module from the heat and / or outward-pointing forces used during this step. The protective element is adapted to protect the electronic module from these specific conditions, ensuring that the electronic module remains undamaged during manufacturing. This protective adaptation is crucial because it emphasizes the dual function of the protective element: not only integrating the electronic module into the bladder but also protecting its integrity from potentially harmful manufacturing conditions. By specifying the use of heat and / or outward-pointing forces, this embodiment defines the operating parameters of the method, thus providing a more comprehensive and robust description of the manufacturing process. This level of detail enhances the precision of the embodiment, ensuring that the method is clearly defined and the role of the protective element is clearly stated. The protective element is adapted to counteract the effects of heat and / or outward-pointing forces, which emphasizes the importance of maintaining the functionality and reliability of the electronic module, which is essential for the overall performance of the bladder and the final ball. Therefore, this implementation not only details the method for forming the bladder, but also emphasizes the protective measures incorporated to protect the electronic modules, thereby contributing to the durability and effectiveness of the final product.

[0019] In some embodiments, the protective element may be a housing of electronic components adapted to withstand the heat and / or outward-pointing forces used in the bladder-forming step.

[0020] This implementation introduces a specific enhancement to the method for manufacturing the bladder of a ball, with a particular focus on the protective element associated with the electronic module. In this context, the protective element is identified as the housing of the electronic component. This housing is specifically adapted to withstand the heat and / or outward-directing forces applied during the process of forming the bladder onto the inner wall of the mold. Introducing this housing as a protective element brings several new features and communication mechanisms between components. The primary function of the housing is to act as a protective barrier for the electronic component, ensuring its integrity and functionality are maintained during the manufacturing process. This is crucial because the manufacturing process involves the application of heat and pressure, which can damage sensitive electronic components. By adapting the housing to withstand these conditions, the electronic component is shielded from adverse effects, thereby enhancing the durability and reliability of the final product. In this case, communication between components involves the interaction between the bladder material and the housing during the forming process. The bladder material must be formed around the housing in a manner that creates recesses for the electronic component, ensuring its secure containment within the bladder. This interaction is facilitated by the design of the housing, which must be compatible with the bladder material to allow for proper adhesion and formation. This new feature of the outer shell, capable of withstanding heat and outward forces, ensures that the electronic components are unaffected by manufacturing conditions, thus maintaining their operational capability. This is especially important for sports balls, where electronic components are used for tracking or monitoring purposes, and any damage could impair their function. Overall, the introduction of a heat-resistant shell as a protective element enhances the robustness of the electronic modules within the bladder, ensuring that the manufacturing process does not compromise the performance of the electronic components, thereby contributing to the overall quality and reliability of the sports ball.

[0021] In some embodiments, electronic components may be removably attached during the bladder-forming step.

[0022] This specific communication mechanism between components allows electronic components to be separated and reattached as needed, providing flexibility in the manufacturing process. The removable attachment feature brings several advantages to the manufacturing method. It facilitates easier maintenance and replacement of electronic components, ensuring that if a component fails or requires an upgrade, it can be easily removed and replaced without discarding the entire bladder.

[0023] In some embodiments, electronic components may be provided via assembly devices (preferably pins) of the mold.

[0024] This feature introduces a new aspect to the manufacturing method of bladders for balls (especially sport balls) by specifying how electronic components are positioned and secured during the manufacturing process. The use of assembly devices such as pins ensures that the electronic components are accurately placed on the inner wall of the mold before the unformed bladder is inserted. This precise positioning is crucial for subsequent steps where the bladder is formed onto the inner wall of the mold and simultaneously onto a protective element, resulting in the bladder wall—forming a recess around the electronic components. Introducing this assembly mechanism enhances the reliability and consistency of the manufacturing process by providing a stable and repeatable method for positioning the electronic components. This not only improves the structural integrity of the bladder but also ensures that the electronic components are securely encased within the bladder, protecting them from potential damage during use. Furthermore, the use of pins or similar assembly devices simplifies the manufacturing process by reducing the need for additional alignment steps or complex positioning equipment. This can lead to increased efficiency and reduced production costs. Therefore, this embodiment adds significant improvements to the method by detailing a practical and effective way to integrate electronic components into the bladder, ensuring both precision and protection.

[0025] In some embodiments, the unformed bladder may include a deflated bladder, a bladder preform, or virgin bladder material.

[0026] Each of these embodiments, with its specific further features, and its advantages will be explained below.

[0027] This embodiment of the deflated balloon bladder introduces a specific mechanism for bladder formation—by utilizing a deflated balloon bladder and combining the steps of injecting gas into the bladder and applying heat to it. This method for manufacturing bladders for balls (particularly sports balls) involves electronic modules with protective elements. The novel feature of this embodiment is the use of a deflated bladder, which is then inflated by injecting gas. This process allows for more controlled and precise bladder formation around the electronic components. Applying heat to the deflated balloon bladder helps mold the bladder material, ensuring it accurately conforms to the inner wall of the mold and the protective elements. This results in a cavity forming in the bladder wall around the electronic components. The combination of gas injection and heat application ensures the bladder material is sufficiently flexible and can be effectively shaped, enhancing the integration of the electronic components within the bladder. This method provides a more efficient and reliable way to manufacture bladders with embedded electronic components, ensuring these components are securely housed within the bladder and protected from external forces. Using a subsequently inflated deflated balloon bladder allows for better control over the thickness and uniformity of the bladder wall, which is crucial for the ball's performance and durability. Gas injection and heat application work together to achieve the desired bladder shape and structure, ensuring the electronic module is properly encapsulated and protected. This method also simplifies the manufacturing process by reducing the number of steps required to form the bladder and integrate the electronic components, potentially reducing production costs and improving overall product quality. The introduction of these specific communication mechanisms between components—i.e., deflated bladder, gas injection, and heat application—enhances the functionality and reliability of the manufactured bladder, making it ideal for use in sports balls with embedded electronic modules.

[0028] In some embodiments, the deflated bladder may be attached to a gas injection device (preferably a valve).

[0029] This implementation introduces a specific communication mechanism between components by attaching a deflated bladder to a gas injection device (preferably a valve). This new feature enhances the method of manufacturing bladders by providing a more precise and controlled method of inflating the bladder during the manufacturing process. Including a gas injection device (such as a valve) allows for regulation of the gas flow into the bladder, ensuring that the bladder is properly inflated to the desired pressure and shape. This feature is particularly important in the context of forming the bladder onto the inner wall of the mold and simultaneously onto the protective element, as it ensures that the bladder wall accurately conforms to the mold and the electronic components. By attaching the deflated bladder to the gas injection device, this method facilitates the creation of cavities around the electronic components, which is crucial for protecting the electronic modules within the bladder. Using a valve as the preferred gas injection device provides additional advantages such as ease of use, reliability, and the ability to maintain consistent inflation pressure. This feature also contributes to the overall durability and performance of the bladder, as it ensures that the bladder is formed with uniform thickness and strength. Furthermore, attaching the deflated bladder to the gas injection device simplifies the manufacturing process—by reducing the need for manual intervention and minimizing the risk of error. This enhancement aligns with the overall goal of the method: to produce high-quality bladders—containing electronic modules with protective elements—thereby improving the ball's functionality and lifespan. In summary, this embodiment adds a key feature by incorporating a gas injection device (preferably a valve) to inflate the bladder during formation, thereby improving the precision, efficiency, and reliability of the bladder manufacturing process.

[0030] In some embodiments, the deflated bladder may contain an elastomer, preferably rubber, more preferably butyl rubber.

[0031] This material specification introduces several new features and communication mechanisms between components. The use of elastomers, particularly rubber, enhances the bladder's flexibility and durability, crucial for maintaining the integrity of the electronics module during manufacturing and subsequent ball use. Elastomers are known for their elastic properties, allowing the bladder to stretch and conform to the mold and protective elements without compromising the structural integrity of the electronics. The preference for rubber, and more specifically butyl rubber, further refines these properties. Butyl rubber is known for its excellent air-holding capacity, particularly advantageous for sports balls requiring consistent inflation levels. This material choice ensures the bladder maintains its shape and function over time, even under repeated stress. Furthermore, the heat and chemical degradation resistance of butyl rubber provides an extra layer of protection for the electronics module, ensuring it remains firmly held within the cavities formed by the bladder. The specific choice of butyl rubber also contributes to a more seamless integration of the electronics with the bladder, as the material's properties allow for more precise and secure cavities to be formed around the electronics module. This enhances the ball's overall reliability and performance, as the electronics are less likely to shift or be damaged during use. In summary, this implementation designates elastomers (particularly butyl rubber) as the material for the bladder of a bleed ball, introducing significant enhancements in flexibility, durability, air retention, and protection of the electronic modules, thereby optimizing the method for manufacturing the bladder of the ball.

[0032] In some embodiments, a bladder preform or virgin bladder material may be used, and the steps of forming the bladder include a blow molding process for forming the bladder.

[0033] This implementation introduces a specific mechanism for forming the bladder, involving the use of a bladder preform or virgin bladder material in conjunction with a blow molding process. The method builds upon this by specifying the material state of the bladder prior to the forming process and the specific techniques used to shape it. Blow molding is a manufacturing method in which soft plastic is inflated into a mold cavity using air pressure to form the desired shape. By employing this process, the method ensures that the bladder wall is formed precisely around the electronic components and their protective elements, creating a recess that firmly houses the electronic module. This technique enhances the precision and consistency of bladder formation, which is crucial for maintaining the integrity and functionality of the electronic components within the sports ball. Furthermore, using a bladder preform or virgin bladder material allows for better control over the material properties and thickness of the bladder wall, which can be customized to specific performance requirements. This feature brings additional versatility and reliability to the manufacturing process, ensuring that the final product meets stringent quality standards. Integrating the blow molding process into this method also suggests potential improvements in production efficiency and scale, as the technology is well-suited for high-volume manufacturing. Overall, this implementation refines the method by detailing specific forming processes and material states, thereby enhancing the practicality and effectiveness of the manufacturing process for bladders (used in sports balls containing electronic modules).

[0034] In some embodiments, a bladder preform can be used.

[0035] This implementation introduces a specific mechanism for forming the bladder by specifying the use of a bladder preform and involving injection-blow molding technology. This injection-blow molding method requires injecting molten material into a mold to create a preform, which is then blown into its final shape within the mold. This process allows for precise control over the thickness and uniformity of the bladder walls, ensuring the bladder is accurately formed around the electronic components and their protective elements. Combining the use of a bladder preform with injection-blow molding enhances the manufacturing process by providing a more consistent and reliable method for integrating electronic modules into the bladder. This technology also potentially improves the durability and performance of the bladder by ensuring strong and well-formed recesses around the electronic components. Utilizing the novel features of the injection-blow molding process brings several advantages, including improved material distribution, enhanced structural integrity, and the ability to produce complex shapes with high precision. This method is particularly beneficial for manufacturing sports balls, where the uniformity and strength of the bladder are critical to performance. By specifying the use of a bladder preform and injection-blow molding, this implementation adds a layer of uniqueness to the manufacturing method, highlighting a sophisticated technology that improves the overall quality and functionality of the bladder. This implementation builds upon this by detailing the specific methods for forming the bladder, thus providing a clearer and more detailed description of the manufacturing process. Including this specific molding process emphasizes the importance of precision and reliability in the production of bladders for sports balls, ensuring that electronic components are securely and effectively integrated into the final product.

[0036] In some embodiments, the bladder preform can be preheated.

[0037] In this context, the method involves: providing an electronic component on the inner wall of a mold, inserting an unformed bladder into the mold, and forming the bladder onto the inner wall of the mold and simultaneously onto a protective element, thereby adapting the bladder wall to form a cavity around the electronic component. Preheating the bladder preform is added as a specific mechanism to enhance the manufacturing process. Preheating can facilitate the forming process by increasing the flexibility and malleability of the bladder material, making it easier to conform to the contours of the mold and the protective element. This can result in a more precise and robust encapsulation of the electronic component within the bladder, ensuring a uniform and robust cavity formed around the electronic component.

[0038] In some embodiments, virgin bladder material may be used, and the steps of forming the bladder include an extrusion blow molding process for forming the bladder.

[0039] This method involves extruding a molten tube of virgin bladder material and then enclosing it within a mold. Air is blown into the tube, causing it to expand and conform to the shape of the mold, including the inner walls and protective elements housing the electronic components. The extrusion blow molding process ensures that the bladder wall forms cavities around the electronic components, thus seamlessly integrating the electronic modules into the bladder. This method provides a more efficient and precise way to manufacture bladders because it allows for the simultaneous formation of the bladder and the encapsulation of the electronic components within protective cavities. Combining virgin bladder material with the extrusion blow molding process enhances the structural integrity and durability of the bladder, ensuring that the electronic components are securely housed and protected from external forces. The process also allows for better control over the thickness and uniformity of the bladder wall, which is crucial for maintaining the ball's performance and lifespan. By specifying the use of virgin bladder material and the extrusion blow molding process, this implementation adds a layer of uniqueness and technical detail to the method, highlighting the advantages of this manufacturing technology in producing high-quality bladders with integrated electronic components. This method not only simplifies the manufacturing process but also improves the overall quality and reliability of the final product.

[0040] In some embodiments, the original bladder material to be inserted may be a preform that is extruded before being formed by pressure from injected gas.

[0041] The novel feature of this implementation is that the original bladder material is specified as a preform extruded before the forming process. This preform is then formed using the pressure of injected gas. Introducing the preform as the original bladder material and using gas pressure to form it adds a layer of uniqueness to the manufacturing process. The preform, as an extruded material, implies a preliminary forming or preparation stage before it is inserted into the mold. This preparation contributes to the uniformity and quality of the final bladder. Using gas pressure to form the preform reflects the blow molding process, a common technique for manufacturing hollow objects. This method ensures that the bladder material closely conforms to the internal contours of the mold, including the protective elements of the electronic modules. The gas pressure helps to expand the preform against the mold wall, ensuring that the bladder wall forms recesses around the electronic components, as described in this aspect. This specific mechanism of forming using an extruded preform and gas pressure enhances the precision and consistency of bladder formation, potentially improving the integration of the electronic modules within the bladder. Therefore, this implementation refines the manufacturing method by specifying the type of original material used and the forming technique, which can lead to improved product performance and reliability.

[0042] In some embodiments, the bladder preform or original bladder material may comprise a thermoplastic polymer, preferably a thermoplastic elastomer.

[0043] The inclusion of thermoplastic polymers as a material choice suggests an emphasis on material properties that can influence the manufacturing process and the final characteristics of the bladder. Thermoplastic polymers are known for their ability to soften repeatedly by heating and harden by cooling, which is advantageous in the molding process. This property allows the material to be easily shaped and reshaped, which is particularly beneficial when forming the bladder onto the inner wall of a mold and surrounding the protective element. The preference for thermoplastic elastomers further refines this choice by highlighting a subclass of thermoplastic polymers that exhibits both thermoplastic and elastic properties. Thermoplastic elastomers combine the elasticity of rubber with the recyclability and processing advantages of plastics. This means that the bladder can be both flexible and durable, which is crucial for sports balls that need to withstand repeated impacts and maintain their shape. Choosing thermoplastic elastomers may also mean enhanced performance characteristics, such as improved abrasion and tear resistance, better flexibility at different temperatures, and potentially lighter weight—all desirable in the context of sports equipment. Furthermore, the use of thermoplastic elastomers can facilitate the integration of electronic modules by providing a more adaptable and resilient environment for electronic components, thereby enhancing their protection and extending their service life. This material choice may also impact manufacturing efficiency, potentially allowing for faster production cycles and reduced material waste due to the recyclable nature of thermoplastic elastomers. Overall, this implementation enriches the approach by specifying a material that not only supports the functional requirements of the bladder but also aligns with manufacturing efficiency and enhanced product performance.

[0044] In some embodiments, a temperature ranging from 80°C to 220°C, preferably from 120°C to 200°C, and more preferably from 140°C to 180°C, may be applied.

[0045] The specified temperature range is between 80°C and 220°C, preferably between 120°C and 200°C, and more preferably between 140°C and 180°C. This new feature allows for precise control of thermal conditions during manufacturing, which can significantly affect the quality and properties of the bladder. By specifying the temperature range, this embodiment ensures that the material properties of the bladder are optimized for formation around the electronic components and protective elements. The controlled temperature range may help achieve desired mechanical properties, such as elasticity, durability, and the ability to form a strong cavity around the electronic components. Furthermore, maintaining the temperature within this range helps prevent defects—which can occur due to inappropriate thermal conditions—such as warping, incomplete formation, or weak bonding between the bladder material and the electronic components. This feature also implies a certain level of precision in the manufacturing process, which can lead to consistent and reliable production results. Including this temperature range in the embodiment highlights the importance of thermal management in this method, ensuring that the bladder is correctly formed and functions as intended when integrated into the ball. This specific temperature control can also affect curing time and the overall efficiency of the manufacturing process, potentially reducing production time and costs while maintaining high-quality standards. Therefore, this implementation adds a key aspect of thermal regulation to the method, enhancing the overall robustness and effectiveness of the bladder manufacturing process.

[0046] In some embodiments, the step of forming the bladder includes a rotational molding process.

[0047] By incorporating rotational molding, this method ensures a more uniform distribution of material forming the bladder, resulting in a more consistent and durable final product. Rotational molding, also known as rotomolding, involves rotating a mold around two mutually perpendicular axes, allowing material to be evenly coated onto the inner surface of the mold. This process is particularly beneficial in ensuring that the bladder walls form cavities around the electronic components with high precision and uniformity. Rotational molding also allows for the creation of complex shapes and seamless integration of electronic modules and their protective elements into the bladder structure.

[0048] In some embodiments, a softening material or powder material may be inserted during the step of forming the bladder, and the mold may be rotated about at least two axes during this step.

[0049] This embodiment enhances the manufacturing process by allowing for a more uniform and consistent formation of the bladder around the electronic module and its protective components. The introduction of softening or powdered materials signifies a change in the state of the bladder material, facilitating its adaptation to the shape of the mold and electronic components. This is crucial for ensuring the bladder wall forms precise recesses around the electronic components, as described in this aspect. Rotation of the mold around at least two axes is an important complement to this method, as it ensures a uniform distribution of the bladder material. This rotational motion is necessary to achieve uniform thickness and consistency of the bladder wall, which is essential for maintaining the integrity and functionality of the bladder within the ball. Biaxial rotation may enhance the coverage and adhesion of the bladder material to the electronic module and its protective components, thereby improving the durability and performance of the final product. This feature also implies increased manufacturing process efficiency, potentially reducing the time and resources required to achieve the desired bladder configuration. By incorporating these specific mechanisms, this embodiment adds a layer of complexity to the manufacturing method, addressing potential challenges related to material distribution and component integration within the bladder. Introducing these features not only refines the process but also potentially improves the quality and reliability of the ball, ensuring the electronic module is securely housed within the bladder. This advancement in the method highlights a thoughtful consideration of the complexities involved in manufacturing bladders with integrated electronics, which will ultimately contribute to the development of more advanced and robust sports equipment.

[0050] In some embodiments, the unformed bladder may comprise a thermoplastic polymer, preferably a thermoplastic elastomer.

[0051] By specifying that the unformed bladder is made of a thermoplastic polymer, this embodiment highlights the material's properties, such as its ease of molding and reforming upon heating, which is crucial for the steps of forming the bladder onto the inner wall of the mold and surrounding the protective elements. The preference for thermoplastic elastomers further refines the material selection, emphasizing the need for elasticity and flexibility in the bladder. Thermoplastic elastomers combine the properties of rubber with the processing advantages of plastics, providing durability, resilience, and the ability to withstand repeated deformation. These qualities are extremely important for sports ball bladders, which must withstand significant stress and maintain their shape and function over time. Using thermoplastic elastomers ensures that the bladder can form a strong and protective cavity around the electronic components, enhancing the ball's overall performance and lifespan. Furthermore, the material's compatibility with the molding process ensures seamless integration of the electronic modules, reducing the risk of damage or malfunction. This material selection also facilitates the manufacturing process, allowing for efficient production and consistent quality control. By specifying the use of thermoplastic polymers, particularly thermoplastic elastomers, this embodiment adds a layer of uniqueness and technical detail, enhancing the effectiveness and reliability of the method—in the production of high-quality bladders for sports balls. This material choice is crucial for achieving the desired balance between strength, flexibility, and durability, ensuring that the bladder can perform its intended function while protecting the embedded electronic components.

[0052] In some embodiments, the protective element may comprise at least one of the following: rubber, polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), thermoplastic polyurethane (TPU), or polyamide-imide (PAI).

[0053] These materials are chosen for their properties—which contribute to the durability and functionality of components. For example, rubber offers flexibility and impact resistance, making it suitable for absorbing shocks and protecting electronic components. PC / ABS combines the strength and heat resistance of polycarbonate with the flexibility and processability of ABS, providing a balanced material capable of withstanding mechanical stresses and environmental factors. Pure polycarbonate (PC) is known for its high impact resistance and transparency, which is beneficial in applications requiring visibility of electronic components. Polyphenylene sulfide (PPS) is a high-performance thermoplastic known for its chemical resistance and thermal stability, making it suitable for harsh environments. Polyethylene terephthalate (PET) is a durable and lightweight material with good barrier properties, commonly used in packaging and protective applications. Polyamide (PA), commonly known as nylon, offers excellent mechanical properties, including high tensile strength and abrasion resistance. Thermoplastic polyurethane (TPU) is a versatile material known for its elasticity, transparency, and resistance to oils, greases, and abrasion, making it ideal for protective applications requiring flexibility and durability. Polyamide-imide (PAI) is a high-performance polymer with excellent mechanical strength, thermal stability, and chemical resistance, making it suitable for demanding applications. By specifying these materials, this embodiment enhances the approach by providing options for the protective elements that can be tailored to different performance requirements and environmental conditions, ensuring adequate protection of the electronic components within the bladder during use. This flexibility in material selection allows for optimization of the protective elements based on the ball's specific needs and intended use, thereby improving the overall reliability and lifespan of the electronic modules within the sports ball.

[0054] In some embodiments, the assembly device (preferably a pin) may be adapted to hold the electronic module in place by interlocking the assembly device with the socket in the protective element.

[0055] The assembly device achieves this by interlocking with the socket in the protective element. This interlocking feature ensures that the electronic module remains firmly positioned during manufacturing and within the final product. This aspect outlines a method for manufacturing a bladder comprising an electronic module with a protective element, involving steps such as providing the electronic component on the inner wall of a mold, inserting the unformed bladder into the mold, and forming the bladder onto the inner wall and the protective element to create recesses around the electronic component. This embodiment is built upon to illustrate how the electronic module is held in place, which is crucial for maintaining the integrity and functionality of the electronic component within the bladder. The interlocking mechanism between the assembly device and the socket in the protective element provides a robust and reliable method for securing the electronic module, which is essential for ensuring that the electronic component remains correctly positioned and protected throughout manufacturing and during the ball's use. This feature enhances the overall durability and performance of the ball by preventing displacement or damage to the electronic module.

[0056] In some embodiments, a temperature ranging from 140°C to 260°C, preferably from 160°C to 240°C, and more preferably from 180°C to 220°C, may be applied.

[0057] The introduction of this temperature range brings several new features and communication mechanisms between components. First, specifying the temperature range ensures that the bladder material is adequately formed and bonded around the electronic components and their protective elements. This precise temperature control is crucial for achieving the desired mechanical properties of the bladder, such as flexibility, durability, and the ability to firmly encapsulate the electronic modules. By applying temperatures within the specified range, this method ensures that the bladder material reaches its optimal elasticity, allowing it to fit snugly against the inner wall of the mold and the protective elements. This results in a more uniform and reliable cavity formation around the electronic components, enhancing the overall integrity and performance of the bladder. Furthermore, the specified temperature range may correspond to the thermal properties of the materials used in the bladder and protective elements, ensuring that they do not degrade or lose their functional properties during manufacturing. Including preferred and more preferred temperature ranges further refines the method, providing guidance for obtaining the best possible results. This level of detail in the temperature specification demonstrates a thorough understanding of the materials science involved and highlights the importance of precise thermal management during manufacturing. Overall, the new feature of specifying the temperature range ultimately leads to more reliable and durable sports balls with integrated electronic modules by ensuring consistent and high-quality bladder formation.

[0058] In some embodiments, the step of forming the bulb is performed using heat, wherein protective elements are adapted to protect the electronic module from heat, such that the temperature of the battery of the electronic module does not exceed 100°C, preferably 90°C, more preferably 80°C.

[0059] This protection ensures that the temperature of the battery within the electronic module does not exceed certain thresholds, particularly not exceeding 100°C, preferably not exceeding 90°C, and more preferably not exceeding 80°C. This enhancement significantly strengthens the method by addressing the potential risk of heat damage to the electronic module, particularly its battery, during manufacturing. By specifying temperature limits, this implementation ensures the electronic module remains functional and safe, thereby improving the reliability and durability of the final product. The protective element is crucial for maintaining the integrity of the electronic module while allowing the bladder to form effectively around it. This feature is particularly important in applications where the electronic module is indispensable to the ball's functionality, such as in smart sports balls that track performance metrics. Therefore, this implementation not only outlines a method for incorporating the electronic module into the bladder but also ensures that the module is protected from the potentially destructive effects of heat used during manufacturing. This careful consideration of thermal protection for electronic components highlights an advanced manufacturing approach that strikes a balance between the need for robust physical integration and maintaining electronic functionality.

[0060] In some embodiments, the steps may include: closing the mold before the step; opening the mold after the step; and removing the formed bladder.

[0061] This embodiment introduces an additional process step into the manufacturing method of a ball bladder involving an electronic module with protective elements. The specific communication mechanism between components in this embodiment centers on the interaction between the mold and the bladder during the manufacturing process. This embodiment specifies the following sequence: closing the mold before forming the bladder, opening the mold after bladder formation, and subsequently removing the formed bladder. These steps are crucial because they ensure the bladder is properly formed and the electronic components are securely encased within the bladder's recesses. Closing the mold ensures the unformed bladder is held in place and the forming process occurs under controlled conditions, which is essential for achieving the desired shape and structural integrity. Opening the mold after the forming step allows the formed bladder to be released without damaging the newly formed recesses surrounding the electronic components. Finally, removing the formed bladder is a necessary step to transition from the manufacturing stage to the next stage, ball assembly or quality control. The new features introduced by this embodiment enhance the method by providing a clear and structured approach to handling the mold during the bladder forming process. This ensures the electronic components are adequately protected and the bladder maintains its intended shape and function. By specifying the sequence of closing, opening, and removal, this implementation adds a layer of precision and reliability to the manufacturing process, which is particularly important in applications where electronic components must be securely housed within the bladder. This structured approach also potentially reduces the risk of defects or inconsistencies in the bladder, thereby improving the overall quality and performance of the final product. Furthermore, these steps can facilitate manufacturing efficiency by simplifying mold and bladder handling, which is beneficial in production environments where time and resource management are critical. Overall, this implementation refines the method by integrating these process steps, thereby enhancing the functionality and reliability of the manufactured bladder.

[0062] A second aspect of the invention provides a method for manufacturing a ball (particularly a sports ball), the method comprising the steps of: assembling a shaped bladder manufactured according to any of the foregoing embodiments into the outer shell of a ball while the shaped bladder is in a deflated state again.

[0063] In this context, "formed bladder" means that the bladder has been shaped and constructed according to the specific manufacturing process detailed in the previous embodiments.

[0064] The "shell" is the outer covering of the ball, providing it with durability, texture, and a suitable surface for the sport the ball is intended to be used for.

[0065] The advantage of assembling the bladder into the shell while it is deflated is that it simplifies the insertion process. A deflated bladder is more flexible and easier to handle, allowing it to be correctly positioned within the shell without damage or misalignment. Once the bladder is inside the shell, it can be inflated to the desired pressure, ensuring a tight fit and optimal ball performance. This method improves the efficiency of the manufacturing process and ensures the quality and consistency of the final product.

[0066] A third aspect of the invention provides a ball, particularly a sports ball, comprising a bladder having an electronic module with a protective element adapted to protect the electronic module from heat and / or outward pointing forces used during the formation of the bladder.

[0067] The described subject matter relates to a ball specifically designed for sports purposes, comprising a bladder. The bladder, a flexible, inflatable component, forms the core of the ball, allowing it to maintain its shape and providing the necessary bounce and feel for athletic activities. Within the bladder is an integrated electronic module. This module can serve various functions, such as tracking performance metrics or providing feedback to the user.

[0068] To ensure the electronic module remains functional and undamaged, a protective element is incorporated. This element is specifically designed to shield the electronic module from potential damage caused by heat or outward forces—which may occur during the bladder formation process. The formation process may involve molding or other techniques that apply heat and pressure to shape the bladder. The protective element acts as a barrier, preventing these external factors from adversely affecting the electronic module.

[0069] The advantage of this design is that it allows for the integration of advanced electronic features within the ball without compromising the durability or performance of the electronic components. By protecting the electronic modules, the ball can maintain its intended function and provide users with enhanced features, such as data collection or interactive capabilities, without the risk of damage during manufacturing.

[0070] In some embodiments, the electronic module may be arranged in a recess in the bulb, and the recess is adapted to secure the electronic module. Here, the same advantages explained previously apply.

[0071] In some embodiments, the recess may extend into the bladder and may be adapted to provide sufficient pressure to the lateral surface of the protective element to secure the protective element even when the bladder deflates.

[0072] This implementation introduces a specific communication mechanism between the ball's components, focusing particularly on the interaction between the cavity and the protective element within the bladder. The cavity is designed to extend inwards into the bladder, a key feature ensuring the protective element is securely positioned. This inward extension of the cavity applies sufficient pressure to the lateral surfaces of the protective element. This pressure is crucial as it secures the protective element in place, even in the event of a bladder deflation. A new feature of this implementation is enhanced stability and security of the protective element within the bladder, regardless of its inflation status. This is particularly important for maintaining the integrity and functionality of the electronics housed within the protective element. By ensuring the protective element remains fixed even when the bladder is deflated, this design mitigates the risk of displacement or damage to the electronics at different stages of ball use or handling. This feature enhances the ball's durability and reliability, especially in sports applications where the ball may be subjected to varying pressures and forces. The inward extension of the cavity, and the resulting pressure on the lateral surfaces of the protective element, provides a robust solution to potential problems related to movement or instability of the electronics. Therefore, this implementation solution significantly improves the overall design by addressing the need for a safe and stable housing for the electronic modules inside the bladder, ensuring consistent performance and protection under different conditions.

[0073] In some embodiments, the bladder may comprise butyl rubber and / or a thermoplastic polymer, preferably a thermoplastic elastomer.

[0074] This introduces the specific materials that the bladder can be made from, highlighting the use of butyl rubber and thermoplastic polymers, including thermoplastic elastomers. Butyl rubber is known for its excellent gas impermeability and resistance to heat, chemicals, and ozone, making it an ideal material for maintaining the integrity and durability of the bladder under a variety of conditions. Thermoplastic polymers, especially thermoplastic elastomers, offer a unique combination of rubber-like flexibility and plastic processability. These materials can be repeatedly melted and reformed, providing significant advantages for manufacturing and recycling. Incorporating these materials into the bladder enhances the overall performance of the ball by ensuring its durability and maintaining its shape and function over time. Furthermore, the use of thermoplastic elastomers contributes to the ball's resilience and ability to withstand the forces applied during a match and the heat generated during bladder formation. This implementation builds upon this by specifying the materials that can be used to construct the bladder, providing a more detailed and robust solution for protecting the electronic modules within the ball. The selection of butyl rubber and thermoplastic elastomers meets the need for materials capable of withstanding the physical and thermal stresses involved in the manufacturing process and subsequent use of the ball in sports or other activities. By incorporating these materials, the ball can be better equipped to protect the electronic modules from potential damage caused by heat and outward forces, ensuring the lifespan and reliability of the electronic components housed within the bladder. Therefore, this implementation enhances the ball's functionality and durability, providing a more comprehensive approach to protecting the electronic modules while maintaining the desired performance characteristics of the ball.

[0075] In some embodiments, the protective element may comprise at least one of the following: polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), or polyamide-imide (PAI).

[0076] This implementation introduces a specific material for the protective element of the sphere, designed to protect the electronic module from heat and / or outward-pointing forces during bladder formation. In this context, inter-component communication refers to the interaction between the protective element and the electronic module, as well as the interaction between the protective element and the external environment. The protective element acts as a barrier, ensuring the electronic module remains undamaged by external conditions that could harm it. By specifying materials such as polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), or polyamide-imide (PAI), this implementation highlights the versatility and adaptability of the protective element in providing robust protection. Each of these materials brings unique properties to the protective element. For example, polycarbonate is known for its high impact resistance and thermal stability, making it suitable for protecting the electronic module from mechanical forces and heat. When acrylonitrile-butadiene-styrene is combined with polycarbonate, it enhances the toughness and durability of the protective element, providing a balanced combination of strength and flexibility. Polyphenylene sulfide (PPS) is recognized for its chemical resistance and dimensional stability at high temperatures, which are crucial for maintaining the integrity of the electronic module under thermal stress. Polyethylene terephthalate (PET) offers excellent thermal and dimensional stability as well as moisture resistance, which helps maintain the functionality of the electronic module under a variety of environmental conditions. Polyamides and polyamide-imides are known for their strength, toughness, abrasion resistance, and heat resistance, making them suitable for applications where protective elements are subjected to harsh conditions. By incorporating these materials, the protective element not only ensures the safety of the electronic module but also enhances the overall durability and performance of the ball. The selection of these materials allows for customization based on specific requirements, whether focusing on thermal protection, impact resistance, or chemical stability, thus broadening the ball's applicability to various sports and environmental conditions. Therefore, this implementation expands the scope of this aspect by detailing the material composition of the protective element, providing a comprehensive solution to the challenges posed by the bladder formation process and the ball's operating environment. Attached Figure Description

[0077] Figure 1A An embodiment of the mold is shown.

[0078] Figure 1B An embodiment of a mold with electronic components and protective elements is shown.

[0079] Figure 1C This illustrates an embodiment in which the bladder is being formed in a mold having electronic modules and protective elements.

[0080] Figure 1D This illustrates one embodiment of a bladder within a mold, accompanied by an electronic module and protective elements.

[0081] Figure 1E An embodiment of a bladder with electronic modules and protective elements is shown.

[0082] Figure 1F An embodiment of a bladder with a bladder and an electronic module is shown.

[0083] Figure 1G An embodiment of a bladder with electronic modules and protective elements is shown. Detailed Implementation

[0084] Possible embodiments of different aspects of the present invention are described in the following detailed description primarily with reference to tools and methods for manufacturing bladders for balls (particularly sports balls), the bladder having an electronic module with protective elements. However, it should be emphasized that the present invention is not limited to these embodiments. Rather, it can be used for different types of sports equipment.

[0085] Further reference is made to the fact that only specific embodiments of the invention may be described in more detail below. However, those skilled in the art will understand that optional features and possible modifications described with reference to these specific embodiments may be further modified and / or combined with each other in different ways or in different sub-combinations without departing from the scope of the invention. Individual features may also be omitted if they are not essential to obtaining the desired result. To avoid repetition, the explanations in the preceding sections also apply to the detailed description below.

[0086] Figure 1A -G presents schematic diagrams of embodiments of the present invention for manufacturing a bladder 100 for a ball. Specifically, these embodiments illustrate possible movements of the mold 130 until the bladder 100, having an electronic module 110 with a protective element 120, is manufactured.

[0087] Figure 1A The illustration shows a cross-sectional view of mold 130 used in the manufacturing process of a bladder, highlighting the components involved in bladder formation. Mold 130 is depicted in an exploded view, comprising two hemispherical mold halves. These mold halves are designed to surround an unformed bladder during manufacturing, facilitating the formation of the bladder into its desired shape.

[0088] Mold 130 is designed to accommodate the different stages of the bladder forming process. Initially, an unformed bladder (which can be a deflated bladder, a bladder preform, or raw bladder material) is inserted into mold 130. The mold half is then closed to encapsulate the bladder material. In the subsequent molding process, heat and / or pressure are applied to shape the bladder material against the inner surface of the mold half, simultaneously forming a recess around the electronic module. This recess is customized to conform to the shape of the electronic module, ensuring a secure fit and optimal protection.

[0089] Figure 1B exist Figure 1A The cross-sectional view illustrates how the electronic component 110 is provided in the lower half of the mold 130, which is placed on the inner wall of the mold 130.

[0090] The electronic module 110 is secured within the mold 130 by an assembly device (denoted by numeral 150). The assembly device 150 holds the electronic module 110 in place during the molding process. The assembly device 150 is strategically positioned to ensure that the electronic module 110 is embedded within the bladder wall once the molding process is complete.

[0091] The electronic module 110 has a protective element 120 that shields the electronic module 110 from the heat and outward forces applied during bladder formation.

[0092] The protective element 120 is shown as being integrated with the electronic component 110 to ensure that the component is adequately protected during the molding process.

[0093] The design of mold 130—including gas injection device 160—is crucial for maintaining the integrity of electronic module 110 throughout the manufacturing process. Protective elements 120 of electronic module 110 can be constructed from materials capable of withstanding the thermal and mechanical stresses encountered during bladder formation. These materials may include: polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), or polyamide-imide (PAI).

[0094] Next to electronic component 110, an assembly device 150 is illustrated. This assembly device 150, which may be a pin or similar fastener, is used to hold electronic component 110 in proper position within mold 130. Assembly device 150 interlocks with a socket in protective element 120 to ensure that electronic component 110 remains firmly positioned during molding.

[0095] The upper half of the mold 130 is characterized by the aforementioned gas injection device 160, which is likely a valve or similar device. This gas injection device 160 is used to inject gas into the unformed bladder, promoting its expansion and conforming to the inner wall of the mold 130 and surrounding the protective element 120. The gas injection device 160 is strategically positioned to ensure uniform gas distribution, promoting uniform bladder formation.

[0096] Figure 1C exist Figure 1A and 1BThe cross-sectional view illustrates how the bladder 100 is inserted into the mold 130. The bladder is unformed and intended to be formed during the manufacturing process. The mold 130 is designed to accommodate the bladder 100, ensuring that it can be formed into the desired shape. A gas injection device 160 is depicted positioned at one end of the bladder 100.

[0097] The lower part of the figure provides a more detailed view of the electronic module placed within mold 130. The electronic module 110 is shown housed within a protective element 120. As mentioned, this protective element 120 is designed to shield the electronic module from heat and forces applied during bladder formation. The protective element 120 may be made of a material capable of withstanding manufacturing conditions, ensuring the integrity of the electronic module 110.

[0098] The figure also shows an assembly device 150, which is intended to accommodate the electronic module 110 and its protective element 120. This assembly device 150 is crucial for securing the electronic module in place during manufacturing and ensuring that it remains in the correct position within the bladder.

[0099] Overall, Figure 1C Detailed views are provided showing the integration of the mold assembly and electronic module within the bladder. The arrangement of the bladder 100, mold 130, electronic module 160, protective element 120, and assembly device 150 is crucial for the successful manufacture of a ball with integrated electronic features. This figure highlights the importance of precisely positioning and protecting the electronic module to ensure its functionality and durability within the final product.

[0100] Figure 1D exist Figure 1A-1C The cross-sectional view illustrates how the mold closes.

[0101] The bulb 100 is connected to a gas injection device 160, which is used to inflate or deflate the bulb 100. The gas injection device 160 is located at the bottom (dee) of the bulb 100, adjacent to the electronics module 110. This configuration allows easy access to the gas injection device 160 for inflation purposes while maintaining the integrity and functionality of the electronics module 110.

[0102] Figure 1E The illustration shows how the bladder 100 is inflated, so that the bladder 100 is formed on the inner wall of the mold 130 and simultaneously on the protective element 120, thereby adapting the bladder wall 105 to form a recess 140 around the electronic component 120.

[0103] The bladder 100 forms the main structure of the ball. It is depicted as a spherical solid, which is typical for a moving ball, providing the necessary shape and volume.

[0104] Inside the bladder is an electronic module 110. This module is positioned within a recess 140—indicated by the dashed circle—which is formed as part of the bladder structure. The recess 140 is designed to securely house the electronic module, ensuring it remains in place even when the bladder is deflated. The recess 140 is strategically positioned to minimize interference with ball performance while providing adequate protection for the electronic module.

[0105] The electronic module 110 is further protected by a protective element 120. As mentioned, the protective element 120 is crucial for protecting the electronic module from potential damage caused by heat and outward forces encountered during the bladder manufacturing process. The protective element 120 may be composed of materials capable of withstanding such conditions, ensuring the integrity and functionality of the electronic module.

[0106] Overall, Figure 1E The integration of the electronic module 120 within the bladder 100 of the ball is described in detail. This arrangement ensures the module is protected and securely housed, allowing the ball to maintain its intended functional and performance characteristics. The use of the protective element 120 and the strategically designed recess 140 highlights the careful consideration given to the placement and protection of the module within the ball's structure.

[0107] Figure 1F The illustration shows how the mold 130 is opened after the bladder 100 is formed.

[0108] The electronic module 110 is positioned within a recess 140 formed in the bladder 100. The recess 140 is designed to securely accommodate the electronic module 110, ensuring that it remains in place even when the bladder deflates.

[0109] The protective element 120 is strategically positioned to provide optimal protection for the electronic module 110. The recess 140 is shaped to conform to the dimensions of the electronic module 110, ensuring a tight fit to prevent movement and potential damage. The protective element 120 may be constructed from materials such as polycarbonate, polyamide, or other thermoplastic polymers known for their durability and heat resistance.

[0110] Figure 1G The illustration shows the formed bladder 100, which has electronic components 110 and protective elements 120 in the recess 140.

[0111] The recess 140 is formed on the inside of the bladder 100 to ensure that the electronic module 110 is securely positioned. The recess 140 is designed to conform to the shape of the electronic module 110, providing a tight fit that helps maintain the module's position even when the ball is deflated. This design is crucial to preventing the electronic module from shifting during ball use, which could otherwise lead to damage or malfunction.

Claims

1. A method for manufacturing a bladder for a ball, particularly a sports ball, the bladder including an electronic module with protective elements, wherein the method comprises the following steps: (a.) Providing electronic components on the inner wall of the mold; (b.) Insert the unformed bladder into the mold; as well as (c.) The bladder is formed onto the inner wall of the mold and simultaneously onto the protective element, such that the bladder wall is adapted to form a recess around the electronic component.

2. The method according to the preceding claim, wherein, The electronic component is arranged on the outside of the bulb wall and fixed inside the recess after step (c).

3. The method according to any one of the preceding claims, wherein, After step (c.), the shape of the recess is adapted to conform to the shape of the electronic component.

4. The method according to any one of the preceding claims, wherein, Step (c.) is performed by using heat and / or an outward pointing force, and wherein the protective element is adapted to protect the electronic module from the heat and / or the outward pointing force used in step (c.).

5. The method according to the preceding claim, wherein, The protective element is the housing of the electronic component, which is adapted to withstand the heat and / or the outward pointing force used in step (c.).

6. The method according to any one of the preceding claims, wherein, The electronic component is removably attached in step (a.).

7. The method according to any one of the preceding claims, wherein, The electronic components are provided by assembly devices of the mold, preferably pins.

8. The method according to any one of the preceding claims, wherein, The unformed bladder includes a deflated bladder, a preformed bladder, or raw bladder material.

9. The method according to the preceding claim, wherein, Using a deflated bladder, wherein step (c.) includes injecting gas into the deflated bladder and applying heat to the deflated bladder.

10. The method according to the preceding claim, wherein, The deflated bladder is attached to a gas injection device, preferably a valve.

11. The method according to any one of claims 9 or 10, wherein, The deflated bladder contains an elastomer, preferably rubber, more preferably butyl rubber.

12. The method according to claim 8, wherein, The bladder preform or virgin bladder material is used, and step (c.) includes a blow molding process for forming the bladder.

13. The method according to the preceding claim, wherein, The use of a bladder preform, wherein step (c.) includes an injection-blow molding process for forming the bladder.

14. The method according to the preceding claim, wherein, The bladder preform is preheated.

15. The method according to claim 12, wherein, The original bladder material is used, and step (c.) includes an extrusion blow molding process for forming the bladder.

16. The method according to the preceding claim, wherein, The inserted bladder material is a preform, which is extruded before being formed by pressure from injected gas.

17. The method according to any one of claims 12 to 16, wherein, The bladder preform or the original bladder material comprises a thermoplastic polymer, preferably a thermoplastic elastomer.

18. The method according to any one of claims 8 to 17, wherein, The applied temperature ranges from 80°C to 220°C, preferably from 120°C to 200°C, and more preferably from 140°C to 180°C.

19. The method according to any one of claims 1 to 7, wherein, Step (c.) includes a rotary molding process.

20. The method according to the preceding claim, wherein, In step (b.), a softening material or powder material is inserted, and during step (c.), the mold is rotated about at least two axes.

21. The method according to claim 18 or 19, wherein, The unformed bladder contains a thermoplastic polymer, preferably a thermoplastic elastomer.

22. The method according to any one of the preceding claims, wherein, The protective element comprises at least one of the following: rubber, polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), thermoplastic polyurethane (TPU), or polyamide-imide (PAI).

23. The method according to claim 7, wherein, The assembly device, preferably a pin, is adapted to hold the electronic module in place by interlocking the assembly device with the socket in the protective element.

24. The method according to any one of claims 19 to 22, wherein, The applied temperature ranges from 140°C to 260°C, preferably from 160°C to 240°C, and more preferably from 180°C to 220°C.

25. The method according to any one of claims 4 to 24, wherein, Step (c.) is performed by using heat, wherein the protective element is adapted to protect the electronic module from the heat in step (c.) such that the temperature of the battery of the electronic module does not exceed 100°C, preferably 90°C, more preferably 80°C.

26. The method according to any one of the preceding claims, further comprising the following steps: Close the mold before step (c.); The mold is opened after step (c). as well as Remove the shaped bladder.

27. A method for manufacturing a ball, particularly a sports ball, the method comprising the steps of: The shaped bladder manufactured according to any one of the preceding claims is assembled into the outer shell of the ball when the shaped bladder is in a deflated state again.

28. A ball, particularly a sports ball, the ball comprising a bladder having an electronic module with a protective element, wherein the protective element is adapted to protect the electronic module from heat and / or outwardly pointing forces used during the formation of the bladder.

29. The ball according to the preceding claim, wherein, The electronic module is disposed in a recess in the bulb, and the recess is adapted to fix the electronic module.

30. The ball according to the preceding claim, wherein, The recess extends into the bladder and is adapted to provide sufficient pressure to the lateral surface of the protective element to secure the protective element, even when the bladder is deflated.

31. The ball according to any one of claims 28 to 30, wherein, The bladder contains butyl rubber and / or a thermoplastic polymer, preferably a thermoplastic elastomer.

32. The ball according to any one of claims 28 to 31, wherein, The protective element comprises at least one of the following: polycarbonate / acrylonitrile-butadiene-styrene (PC / ABS), polycarbonate (PC), polyphenylene sulfide (PPS), polyethylene terephthalate (PET), polyamide (PA), or polyamide-imide (PAI).

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