Ball, especially football, and method for manufacturing a ball

Abstract

Ball (11), in particular a football, having: a. a shell with a plurality of panels (12a, 12b, 12c, 12d) on the outside of the shell, wherein at least one panel of the plurality of panels has a pseudoseam (22) which extends over at least part of an outer surface of the panel, wherein b. the panels (12a, 12b, 12c, 12d) are arranged such that at least one gap (21) is created between at least two adjacent panels (12a, 12b), and wherein c. the at least one gap (21) is at least partially filled with a filling material (13), wherein the gap is such that the at least two adjacent panels do not touch in the area of ​​the gap, d. wherein at least one pseudoseam (22) is filled with the filling material.

Description

1. Technical field

[0001] The present invention relates to a ball, in particular a football, and a method for manufacturing such a ball. 2. State of the art

[0002] Balls, especially those used in ball sports like football, are typically made either by sewing together individual pieces of leather or synthetic leather, or by gluing panels, usually made of plastic, onto a bladder or a carcass placed over a bladder for reinforcement. The latter type of ball is also known as laminated balls.

[0003] A sewn ball is made from numerous pieces of leather or imitation leather, the edges of which are folded inwards and sewn together with a needle. By carefully selecting the geometry of the leather or imitation leather pieces, an almost spherical shape is achieved during sewing. Fabric is usually glued to the back of the leather or imitation leather pieces for reinforcement. A bladder, typically made of rubber, is usually inserted into the hand-sewn ball to ensure airtightness. The bladder also has a valve for inflating the ball. A carcass made of fabric or one or more circumferential threads can be placed between the bladder and the leather or imitation leather pieces to reinforce and protect the bladder.

[0004] In a ball sewn together in this way, the edges of the leather or imitation leather pieces are folded inwards and then sewn to adjacent, i.e., abutting, leather or imitation leather pieces. This creates a seam on the outside of the ball in the form of a groove between adjacent leather or imitation leather pieces. Typically, such a seam has a width of approximately 2.5 mm at its top (i.e., on the side facing away from the center of the ball) and a depth of approximately 2.0 mm.

[0005] It has been found that the seams of stitched balls have a positive effect on their aerodynamic properties by reducing air resistance and thus enabling greater flight distances. This is attributed to small turbulences on the surface of the flying ball. Furthermore, the seams contribute positively to the ball's gripping properties, meaning the ball is easier to grasp and control.

[0006] Because the ball has a three-dimensional shape, it cannot be machine-sewn but must be sewn by hand. This has the disadvantage that such hand-sewn balls are subject to significant manufacturing variations, which can affect quality and lead to variations in weight, size, shape, flight, and gripping characteristics. Another disadvantage of hand-sewn balls is the considerable time required for their production.

[0007] These disadvantages are partially overcome by laminated balls, as the panels do not need to be sewn together by hand. The manufacturing variations typical of hand-sewn balls are therefore less pronounced in laminated balls. Furthermore, a laminated ball can be manufactured, at least partially, using appropriate machinery. This, along with the elimination of manual sewing, allows for significantly faster production of laminated balls.

[0008] Laminated balls, however, have inferior flight and grip characteristics compared to hand-stitched balls because the groove between the individual panels is shallower (usually around 1 mm). Furthermore, conventional manufacturing processes for laminated balls offer little or no control over the geometry (i.e., depth, width, cross-sectional profile, etc.) and surface properties (i.e., static friction, feel, roughness, etc.) of this groove.

[0009] US Patent 6,398,894 B1 discloses a method for manufacturing a basketball, which includes, among other things, the following steps: (a) providing a sheet of rubber material; (b) folding, compressing, and cutting the rubber material to form a bladder; (c) attaching a valve to the bladder; (d) inflating the bladder with air and heating the bladder; wrapping the inflated bladder with at least one thread; (f) gluing sheets of rubber to the surface of the wrapped layer; (g) forming a depression at each junction between adjacent sheets of rubber; (h) gluing a thinner and narrower strip than the sheets of rubber at each junction of adjacent sheets of rubber;(i) Heating and curing the relatively large, multiple rubber sheets together with the strips in a mold which has several protruding ribs defined therein to obtain a basketball, the basketball having several relatively concave depressions with two beveled walls defined therein.

[0010] US Patent 3,887,416 A relates to a method for manufacturing a leather-covered soccer ball. The soccer ball is manufactured by taking a bladder wound with nylon cord and covered with a layer of rubber, all of which is common practice, and covering the bladder with several rubber segments, including strips at the seams, areas adjacent to the seams, and a shaped element at each end.

[0011] US Patent 5,542,662 A relates to a sports ball and a corresponding manufacturing process. An inflatable tube is inserted into a cover layer formed from a thin rubber sleeve made of a material that prevents a solution of adhesion promoter from penetrating the cover layer and an inorganic lubricant located between the tube and the cover layer.

[0012] EP 1 080 745 B2 relates to a laminated ball with a bladder onto which numerous pieces of leather are attached, the leather pieces being glued together at their joints. The leather pieces are glued directly to one another, so that when adjacent leather pieces are applied to the bladder, no gaps remain between the leather pieces.

[0013] US Patent 8,574,104 B2 relates to an inflatable sports ball structure and a corresponding manufacturing process. The inflatable sports ball structure comprises an inner bladder, a reinforced carcass, and an outer material layer. The reinforced carcass covers the surface of the inner bladder and has a layer wound from thread. Part of the thread-wound layer is embedded within the reinforced carcass, providing a limiting force toward the inner bladder, while a small remaining portion of the thread-wound layer may be exposed on the outer surface of the reinforced carcass.

[0014] US 4,187,134 A refers to a molded game ball produced by wrapping a layer of fibrous material onto an inflated rubber bladder, applying a film of a rubber compound containing a vulcanizing agent to this layer, embossing a grid of fields onto this layer in a cold mold to indicate where cover segments must be glued so that they do not touch each other around their perimeter, and finally pressing this semi-finished product with glued cover segments in a smooth mold at temperatures for vulcanization.

[0015] US 2013 / 0059683A1 refers to a basketball with a carcass, cover plates, and cover strips. The carcass has an outer surface that defines a first group of channels and cover plate areas between the first group of channels. The plates are positioned over the plate areas and spaced apart from each other. The strips are arranged over the channels. The strips have inner and outer surfaces that extend between the first and second sidewalls.

[0016] US 2 579 294 A relates to a method for manufacturing a sports ball, which includes the steps of gluing together layers of fabric, producing a fabric body from laminated pieces of fabric sewn together with their twisted edges, and inserting a pre-shaped rubber filler strip into the valley formed in the outer surface by the twisted edges.

[0017] US 2,843,383 A refers to sports balls, and in particular basketballs and similar balls with molded channel seams in the surface. Further sports balls of this type are shown in DE 10 2009 016 287 B3 and JP S59-125 578 A.

[0018] The present invention therefore addresses the problem of providing a ball, in particular a football, which is relatively quick, easy and inexpensive to manufacture and which also has very good flight and gripping characteristics, approaching those of a hand-stitched ball, but without the quality variations typical of hand-stitched balls. Furthermore, the flight and gripping characteristics of the ball should be individually adjustable. 3. Summary of the invention

[0019] According to a first aspect of the present invention, this problem is solved by a ball, in particular a football, comprising (a.) a shell with a plurality of panels on the outside of the shell, wherein (b.) the panels are arranged such that at least one gap is created between at least two adjacent panels, and wherein (c.) the at least one gap is at least partially filled with a filling material.

[0020] According to the invention, the ball therefore has at least one gap between two panels. Within the scope of the present invention, a gap is understood to mean that the panels do not touch in the area of ​​the gap, and a space is created between the panels in question. If the gap were not filled with a filling material, the shell on which the panels are arranged would be visible through the gap. However, according to the invention, it is not precluded that two panels form a gap in one area but touch in another area.

[0021] The ball according to the invention can be manufactured relatively quickly, easily, and cost-effectively by, for example, gluing the panels onto a suitable cover (blade or bladder reinforced with a carcass). This can also be done automatically using a suitable machine. Simultaneously, a gap is left between at least two panels, which is filled with filling material. The filled gap thus imitates a seam of a hand-sewn ball and positively influences the ball's aerodynamic properties. The filling material can be precisely positioned within each gap. In this way, certain aerodynamic properties of the ball to be manufactured can be very specifically influenced and defined. The height and / or width of each gap can be individually determined.

[0022] The geometry (i.e., depth, width, cross-sectional profile, curvature, etc.) and surface properties (i.e., static friction, feel, roughness, etc.) of the filled gap can be specifically influenced by both the quantity and the composition of the filler material. For example, a particularly grippy filler material can be used to improve the ball's gripping properties.

[0023] Preferably, the depth of the filled gap is at least 1 mm, more preferably at least 1.5 mm, and further preferably at least 2 mm. The amount of filling material can be precisely controlled to ensure the desired minimum depth of the filled gap is maintained.

[0024] Furthermore, in a ball according to the invention, the gap can be automatically filled by a machine in order to minimize manufacturing variations (and thus variations in aerodynamics and feel) between different balls. Unlike hand-stitched balls, the "seam" (i.e., the filled gap) therefore always has the same cross-section in every ball.

[0025] Unlike conventional laminated balls, these balls further reduce manufacturing variations and allow for precise adjustment of the "seam's" geometry and surface finish to achieve even better flight and grip characteristics. For example, a much wider "seam" can be achieved than is possible with conventional laminated balls, where the adjacent panels butt against each other.

[0026] The filling material can fill the gap in such a way that the outer surface of the casing is completely covered within the gap. This protects the underlying casing and prevents water from penetrating. Unlike a hand-sewn ball, a ball according to the invention does not absorb water.

[0027] According to the invention, the filling material is a hardened material that is liquid before hardening. Liquid filling material is easy to process and fills the gap very well because it adapts to the shape of the gap and flows into it. This makes the ball particularly waterproof.

[0028] The filler material can be polyurethane or silicone. These materials are easy to process, have advantageous surface properties, particularly high friction, and ensure a high degree of water resistance. Polyurethane's material properties, such as viscosity, are especially controllable. Furthermore, polyurethane exhibits a high affinity for the surrounding material, particularly the material of the panels and the casing. Alternatively, other materials, such as resin systems, can also be used as fillers.

[0029] The filling material can contain at least one light-emitting element. This makes the ball highly visible even in low light conditions (e.g., at dusk). Furthermore, the manufactured ball can be customized by choosing specific colors for the light-emitting elements. For example, the light-emitting elements could be selected in specific team colors. LEDs, micro-LEDs, or OLEDs can be embedded in the filling material as light-emitting elements. Alternatively, the filling material could be a phosphorescent or chemiluminescent material that glows particularly brightly in the dark. A business model could therefore involve offering different balls with various embedded light-emitting elements for sale. This would allow customers to purchase balls that glow in specific colors.

[0030] The filling material can also incorporate at least one embedded display from which information can be read. This information could include, for example, data on measured shot speeds, impact forces, flight heights, or game durations. Sensors for measuring such data can be located inside the ball. Alternatively, it is conceivable that information could be entered via a display integrated into the filling material, for example, via a touch function.

[0031] The filling material itself can also be designed as a display. It is possible for the filling material to change color depending on measured information. For example, it is conceivable that the filling material could glow in different colors depending on the measured shot speed or shot strength. Thus, the filling material could glow in one color in a first shot strength range, in a second color in a second shot strength range, and in a third shot strength range in a third color.

[0032] The filling material can contain at least one electronic element. For example, this electronic element could be an RFID or NFC tag that allows information about the ball to be read.

[0033] The filler material can fill 50% or more of the gap's cross-sectional area. This ensures the gap is well sealed and protected from water ingress. At the same time, the unfilled portion of the gap's cross-section remains sufficiently deep to maintain good flight and gripping characteristics.

[0034] It is advantageous if the gap is filled with filler material in such a way that the filler material extends into the area between the beveled webs of the panels. The height of the filler material is preferably greater than the height of the panel side edges and less than the overall height of the panels. The beveled webs extend between the panel side edges and the panel outer surfaces. It is particularly advantageous if the height of the filler material is only slightly greater than the height of the panel side edges. Instead of beveled, the webs can also have a convex or concave shape.

[0035] The height of the filling material is preferably constant along a longitudinal axis of the gap parallel to the surface of the shell.

[0036] At least one of the many panels may have a pseudo-seam extending across at least part of its outer surface. A pseudo-seam is a groove on a panel that outwardly resembles a joint between two panels. With appropriate depth and arrangement, pseudo-seams can positively influence the ball's aerodynamics and feel.

[0037] At least one of the pseudo-seams can be filled with the filling material. In this way, no difference between the gap and the pseudo-seam is visible from the outside, which is advantageous for the appearance, aerodynamics and feel of the ball.

[0038] The stated minimum depression of at least 1 mm, preferably at least 1.5 mm, and more preferably at least 2 mm applies both to the filled gaps and to the at least one pseudoseam.

[0039] The outer layer can be a bladder or a carcass mounted on a bladder. A bladder ensures the necessary airtightness of the ball, while a carcass stabilizes the bladder and protects it from external impacts.

[0040] The present invention also relates to a method for manufacturing a ball, in particular a football, comprising the steps (a.) providing a cover; (b.) providing a plurality of panels; (c.) arranging the plurality of panels on the cover so that at least one gap is created between at least two adjacent panels; and (d.) filling the at least one gap at least partially with a filling material.

[0041] According to the invention, at least two panels are arranged such that a gap is formed between them. Within the scope of the present invention, a gap is understood to mean that the panels do not touch in the area of ​​the gap, and a space is created between the panels in question. If the gap were not filled with a filler material, the surface on which the panels are arranged would be visible through the gap. However, according to the invention, it is not precluded that two panels form a gap in one area but touch in another area.

[0042] The inventive method allows for the relatively quick, simple, and cost-effective production of a ball by, for example, gluing the panels onto a suitable covering (bladder or bladder reinforced with a carcass). This can also be done automatically using a suitable machine. Simultaneously, a gap is left between at least two panels, which is filled with packing material. The filled gap thus imitates a seam of a hand-sewn ball and positively influences the ball's aerodynamic properties.

[0043] The geometry (i.e., depth, width, cross-sectional profile, curvature, etc.) and surface properties (i.e., static friction, feel, roughness, etc.) of the filled gap can be specifically influenced by both the quantity and the composition of the filler material. For example, a particularly grippy filler material can be used to improve the ball's gripping properties.

[0044] Furthermore, the inventive method enables the automatic filling of the gap by means of a machine, in order to minimize manufacturing variations (and thus variations in aerodynamics and feel) between different balls. Unlike hand-stitched balls, the "seam" (i.e., the filled gap) therefore always has the same cross-section in every ball. Moreover, the gaps can be created in a defined manner. Filling the gaps with filling material can also be carried out in a targeted and individual way.

[0045] Unlike conventional manufacturing processes for laminated balls, this method further reduces manufacturing variations and allows for precise adjustment of the geometry and surface finish of the seam to achieve even better flight and grip characteristics. For example, a much wider seam can be achieved than is possible with conventional laminated balls, where the adjacent panels butt against each other.

[0046] The filling step can be carried out by filling the gap with the filling material in such a way that the outer surface of the casing is completely covered within the gap. This protects the underlying casing and prevents water ingress. Unlike a hand-sewn ball, a ball produced according to the inventive method does not absorb water.

[0047] According to the invention, the filling material is liquid, and the method further includes the step of hardening the liquid filling material. Liquid filling material is easy to process and fills the gap very well because it conforms to the shape of the gap and flows into it. This makes the ball particularly watertight.

[0048] According to the invention, the filling material is applied from the outside to fill the at least one gap. For this purpose, for example, a robot can be used, which enables particularly precise filling of the gap.

[0049] The filling material can be applied using a three-dimensional application technique. A three-dimensional application process is one in which an application device moves around a workpiece, in this case the ball, in three dimensions. Alternatively, the ball can be moved around a stationary application device.

[0050] The process can further include the step of forming at least one pseudo-seam on at least one panel, extending over at least part of an outer surface of the panel. A pseudo-seam is a groove on a panel that outwardly gives the appearance of a joint between two panels. With appropriate selection of their depth and arrangement, pseudo-seams can positively influence the aerodynamics and feel of the ball.

[0051] The process can further include the step of filling at least one pseudo-seam with the filling material. In this way, no difference between the gap and the pseudo-seam is visible from the outside, which is advantageous for the appearance, aerodynamics, and feel of the ball.

[0052] The step of filling at least one gap with a filling material can be designed so that the filling material enters the gap from the outside of the shell. For example, a layer of filling material can first be applied to the ball, and then the panels can be pressed onto the ball (e.g., in a mold), so that the filling material enters the gap from below (i.e., from the center of the ball) and fills it.

[0053] The process can further include the step of arranging the numerous panels in a press mold. The use of press molds allows for uniform pressure to be applied when pressing the panels against the casing, thus minimizing manufacturing variations.

[0054] The process can further include the step of positioning the panels against the casing using the press mold, creating at least one gap between at least two adjacent panels and gaps between the panels and the casing. The press mold can have corresponding recesses for inserting the panels. These recesses are spaced so that the panels form the gap when positioned against the casing. In this way, the width of the gap can be set very precisely, and manufacturing variations can be minimized.

[0055] The process can further include the step of injecting the filler material into the gaps or spaces between the panels and the casing. The filler material can bond adjacent panels together as well as the panels to the casing. Additional adhesives are not required.

[0056] The process can further include the following steps: arranging the numerous panels on the shell using a robotic arm, and arranging the shell with the numerous panels in a mold. The robotic arm can position the panels very accurately and precisely on the shell before they are pressed onto the shell under high pressure by the mold.

[0057] The process can further include the step of rotating the press mold, so that the filling material is distributed essentially evenly (i.e., within the limits of unavoidable manufacturing variations) in at least one cavity. This results in the most uniform distribution of the filling material possible within the cavity.

[0058] The filler material can be polyurethane or silicone. These materials are easy to process, have advantageous surface properties, especially high static friction, and ensure a high degree of water resistance.

[0059] The outer layer can be a bladder or a carcass mounted on a bladder. A bladder ensures the necessary airtightness of the ball, while a carcass stabilizes the bladder and protects it from external impacts.

[0060] The step of filling at least one gap with the filling material can include adjusting the amount of filling material per unit of time to the cross-sectional area of ​​the gap. This ensures that the gap is filled as uniformly as possible, compensating for any variations in the gap's width.

[0061] The cross-sectional area of ​​the gap can be detected in real time using an optical method. Determining the cross-sectional area (i.e., in the simplest case, the gap width, assuming the panel thickness is constant) using optical methods is relatively easy and allows for immediate adjustment of the fill quantity per unit of time. 4. Brief description of the drawings

[0062] In the following, aspects of the present invention will be explained in more detail with reference to the accompanying figures. These figures show: Fig. 1: shows an embodiment of a ball according to the invention; Fig. Figure 2 shows a gap as it arises between two panels within the scope of the present invention; Fig. Figures 3a-3d show an embodiment of a method according to the invention for producing a ball; Fig. Figure 4 shows an exemplary process step in which the filling material is applied to the shell from the outside using a robot arm; Fig. 5: a schematic cross-sectional view to illustrate an alternative manufacturing process within the scope of the present invention; and Fig. Figure 6 shows the casing of the ball according to the invention, inserted into a press mold, together with panels. 5. Detailed description of preferred embodiments

[0063] Exemplary embodiments and variations of the present invention are described in more detail below.

[0064] Fig. Figure 1 shows an embodiment of a ball 11 according to the invention. The ball 11 can be, in particular, a football. However, the present invention is not limited to a football and can also be applied to balls for other sports such as basketball, volleyball, rugby, football, tennis, etc.

[0065] Ball 11 features a casing with numerous panels on the outer surface. The casing is in the Fig. 1 is not shown because it is covered by the panels. Of the many panels, the following are in the Fig. 1 two with the reference numbers 12a and 12b respectively. In total, the in Fig. The ball shown in Figure 1 has six panels. In principle, a ball according to the invention can have any number of panels, but at least two. In the exemplary embodiment of the Fig. 1. The ball 11 therefore has further panels which are not designated by a reference numeral. Where the word "multiple" is used within the scope of the present invention, it means "two or more".

[0066] The outer casing can be a bladder, as is commonly used in balls to prevent air from escaping. A bladder can be made of materials such as intestine, latex, or rubber. The bladder can be reinforced with a carcass to prevent damage from external impacts. In this case, the bladder and carcass together form the outer casing. The bladder can be equipped with a valve (not shown in the figures) to allow inflation of ball 11.

[0067] The panels 12a and 12b can be made of leather, imitation leather, or plastic, for example. The panels can be glued, welded, sewn, or attached to the cover using another suitable joining method. For instance, the cover can be completely coated or immersed in an adhesive. The panels 12a and 12b can then be placed onto the cover. Alternatively, only one side of the panels 12a and 12b can be coated with an adhesive, and then the adhesive side can be placed onto the cover. The adhesive material could be, for example, a hot melt adhesive, which is activated by exposure to infrared radiation.

[0068] The panels 12a, 12b are arranged such that at least one gap is created between them. In the exemplary embodiment of the Fig. 1. A gap is created between panel 12a and panel 12b. Within the scope of the present invention, a gap is understood to mean that the panels do not touch in the area of ​​the gap, and a space is created between the panels in question. If the gap were not filled with a filler material according to the invention, the shell on which panels 12a and 12b are arranged would be visible through the gap. However, according to the invention, it is not precluded that two panels form a gap in one area but touch in another area.

[0069] In the exemplary embodiment of the Fig. Figure 1 also shows that at least one gap is filled with a filling material 13. In the exemplary embodiment of Fig. 1. The filling material 13 fills the gap in such a way that the outside of the shell is completely covered within the gap, which is why it is in the Fig. 1 is not visible. The filler material 13 can be a cured filler material or a liquid filler material before curing. For example, the filler material 13 can be polyurethane or silicone.

[0070] In one embodiment of the invention (in the Fig. (1 not shown) the filling material 13 can contain a light-emitting element. This can be, for example, a light-emitting diode, OLED, micro-LED, or a phosphorescent or chemiluminescent material, in particular a material that glows in the dark. Furthermore, it is generally possible to place a light source in the center of the ball and to arrange light guides in the filling material 13 that direct the light from the center of the ball outwards.

[0071] The filling material 13 can contain at least one electronic element (in the Fig. (1 not shown). This could be, for example, an RFID or NFC tag. The RFID or NFC tag can be read by a suitable receiver. For example, the RFID or NFC tag can store information about the ball (e.g., model or serial number, a real-time or origin certificate, etc.).

[0072] In the exemplary embodiment of the Fig. In one embodiment, the filling material 13 completely fills at least one gap, i.e., the underlying shell of the ball 11 is not visible. In another embodiment, however, the filling material 13 might not completely fill the gap, i.e., the underlying shell is visible in at least part of the gap.

[0073] At least one of the many panels may have a pseudo-seam (in the Fig. (1 not shown) which extends over at least part of an outer surface of the panel. A pseudoseam is a groove-shaped depression on the outer surface of a panel 12a, 12b. Unlike a seam on a hand-sewn ball, a pseudoseam is not created by sewing two adjacent panels together, but is formed as a groove on a panel to imitate the seams of hand-sewn balls. Within the scope of the present invention, the pseudoseam can be filled with the filling material 13. The filling material can almost completely fill the pseudoseam.

[0074] The Fig. Figure 2 shows a gap 21, as it is formed between two panels 12a and 12b within the scope of the present invention, and a pseudoseam 22 in cross-section. In the Fig. Figure 2 also shows that the pseudoseam 22, as well as the gap 21, is filled with filler material 13. In the example of the Fig. 2 are the pseudoseam 22 and the gap 21 up to the same height H F filled with filler material so that a minimum depression V M is given. The minimum depth V M The thickness is preferably at least 1.5 mm to ensure optimal flight characteristics of the ball.

[0075] From the outside, the difference between the gap 21 and the pseudo-seam 22 is advantageously not noticeable. Using pseudo-seams, the ball 11 can thus be structured in almost any way. However, it is also conceivable that the height H F of the filling material 13 in the gap 21 and the pseudo-seam 22 and thus also the minimum depression V M are different, so that the gap 21 and the pseudoseam 22 can be visually distinguished from the outside.

[0076] As from Fig. As can be seen in Figure 2, panels 12a and 12b each have parallel panel side edges 23a and 23b, as well as parallel panel outer surfaces 24a and 24b. A beveled web 25a and 25b connects the panel side edges 23a and 23b to the panel outer surfaces 24a and 24b. In the illustrated embodiment, this design creates a funnel-shaped or Y-shaped cross-sectional contour for the gap 21. It is advantageous if the gap, as shown in Figure 2, is shaped as follows: Fig. Figure 2 shows that the area is filled with filler material 13 such that the filler material 13 extends into an area between the beveled webs 25a, 25b. The height H F The filler material 13 is greater than a height H PS the panel side edges 23a, 23b and less than a total height H PG of panels 12a, 12b. It is particularly advantageous if the height H F the filler material 13 is only slightly larger than the height H PS the panel side edges 23a, 23b.

[0077] It is also conceivable that a surface 26 of the filled fill material 13 has a convex or concave curvature, as in Fig. 2. Indicated by dashed lines. A convex or concave curvature can be used to specifically influence the flight characteristics of the manufactured ball. Furthermore, haptic or optical properties can be affected.

[0078] A surface 26 of the filler material 13 in the pseudoseam 22 can also have a convex or concave curvature.

[0079] By the inventive method for producing a ball, as described below, the height H F of the filling material or the minimum depression V M Individually adjustable depending on the desired flight characteristics.

[0080] An embodiment of a method according to the invention for manufacturing a ball, in particular a football, is described below with reference to the Fig. 3a, Fig. 3b, Fig. 3c and Fig. Explained in 3D.

[0081] The process begins with the provision of a shell 31. As already explained, this can be a bladder or a bladder reinforced with a carcass. In the next step, a large number of panels 12a, 12b, 12c, 12d are provided. For example, panels 12a, 12b, 12c, 12d can be die-cut from appropriate leather, imitation leather, or plastic sheets. It is also conceivable that panels 12a, 12b, 12c, 12d could be manufactured using an injection molding process, a thermoforming process, or a 3D printer.

[0082] In a further step, the multitude of panels 12a, 12b, 12c, 12d are arranged on the shell so that at least one gap is created between at least two adjacent panels 12a, 12b, 12c, 12d. In the Fig. 3a Two panels 12a and 12b are arranged on the shell 31. In the Fig. 3b another panel 12c has been arranged on the shell 31 and in the Fig. Finally, a fourth panel 12d has been arranged on the shell 31, so that the shell 31 is almost completely covered, except for the gaps 21 intentionally left between the panels. The gap is designed such that adjacent panels 12a, 12b, 12c, 12d forming the gap do not touch. As described above in connection with Fig. As explained in section 1, the panels can, for example, be glued onto the cover.

[0083] The process finally includes the step of filling at least one gap 21 with a filling material 13, as described in the Fig. 3d shown. The filling step can be carried out such that the filling material 13 fills the gap in such a way that the outside of the shell 31 is completely covered within the gap 21.

[0084] As in the Fig. 3a, Fig. 3b, Fig. 3c and Fig. As shown in the 3D figure, the process also includes the step of forming a pseudo-seam 22 on the panels 12a, 12b, 12c, and 12d, which extends over at least part of an outer surface of the panels 12a, 12b, 12c, and 12d. Instead of on all panels, a pseudo-seam 22 can also be formed on a subset of the panels, for example, on a single panel. The pseudo-seam 22 can be cut or milled into the respective panel 12a, 12b, 12c, or 12d. Alternatively, the pseudo-seam 22 can be formed, for example, during injection molding in the respective panel 12a, 12b, 12c, or 12d.

[0085] As in the Fig. As shown in 3d, the pseudo-seams 22 are also filled with filling material 13 (e.g. polyurethane or silicone based), so that from the outside it is not possible to visually distinguish between the gaps 21 between the respective panels 12a, 12b, 12c and 12d and the pseudo-seams 22 on the respective panels 12a, 12b, 12c and 12d.

[0086] If the filler material 13 is a liquid, the process may further include the step of curing the liquid filler material 13. For example, the filler material 13 can be cured using heat or UV light.

[0087] Fig. Figure 4 shows an exemplary process step in which the filler material 13 is applied to the shell 31 from the outside by means of a robot arm 41 in order to fill at least one gap 21. For this purpose, the robot arm 41 has a nozzle 42 through which liquid filler material 13 is introduced into the gap 21. This process is a three-dimensional application technique. In this manufacturing process, the filler material 13 thus enters the gap 21 from the outside of the shell 31.

[0088] The robot arm 41 can have a sensor (in the Fig. (Figure 4 not shown) which measures the depth and width of the gap 21 during the application of the filler material 13. The amount of filler material 13 applied per unit of time can thus be adjusted at least to the width of the gap 21 in order to obtain a gap 21 filled as uniformly as possible with filler material 13. Alternatively, the sensor can also measure the depth of the gap 21 or completely capture the cross-sectional geometry. Fluctuations in the distance between the panels 12a, 12b, 12c, and 12d can thus be compensated for. The robot arm 41 also preferably includes a dosing device by means of which the dispensing of the filler material 13 can be selectively controlled and monitored.

[0089] An alternative manufacturing process within the scope of the present invention is described below with reference to the schematic cross-sectional view of the Fig. 5 and Fig. Figure 6 shows the process. Here, the panels 12a, 12b, 12c, and 12d are placed into a press mold 51. The press mold 51 is then closed so that the panels 12a, 12b, 12c, and 12d are moved towards a centrally fixed shell 31 (a bladder or a bladder reinforced with a carcass). Alternatively, the multitude of panels 12a, 12b, 12c, and 12d can be arranged on the shell 31, e.g., by a robot arm, and the shell 31 with the multitude of panels 12a, 12b, 12c, and 12d can then be positioned in the press mold. In both alternatives, gaps 21 remain between panels 12a, 12b, 12c and 12d. Simultaneously, gaps 52 remain between panels 12a, 12b, 12c and 12d and the casing 31. Due to the formation of the gaps 52, it is no longer necessary, for example, to coat the casing 31 and / or the panels 12a, 12b, 12c, 12d with an adhesive beforehand.

[0090] Fig. Figure 6 shows the shell 31 inserted into the mold 51, together with the panels 12a, 12b, 12c, and 12d. The shell 31 is pressurized with compressed air via an inlet 61 to prevent it from collapsing. Simultaneously, the mold 51 exerts external pressure on the panels 12a, 12b, 12c, and 12d. Liquid filler material 13 (e.g., liquid polyurethane) is injected through a further inlet 62 in the mold 51 into the gaps 21 between the panels 12a, 12b, 12c, and 12d, as well as into the spaces between the panels 12a, 12b, 12c, and 12d and the shell 31. In this embodiment, the filling material 13 connects both adjacent panels 12a, 12b, 12c, 12d to each other and also connects the panels 12a, 12b, 12c, 12d to the shell 31.

[0091] Alternatively, the gaps 21 could also be filled without a specific shape by applying foam beads and then crosslinking in a heated mold. Filling by applying foam beads is just one example of a possible application method for the filling material 13, in the event that a foamed material is used as the filling material 13. The applied filling material 13 can have different bead shapes.

[0092] In an alternative embodiment of the method, the panels 12a, 12b, 12c and 12d could merely form shells with a transparent outer skin and a decorative film, which would then be placed in corresponding molds, moved into their precisely defined position and subsequently back-foamed with a foamed polyurethane and simultaneously connected to the carcass.

[0093] As in the Fig. As shown in Figure 6, the press mold 51 can be suspended rotatably about a vertical axis 63 and a horizontal axis 64. The process then includes the step of rotating the press mold 51 so that the filling material 13 is distributed substantially uniformly (i.e., within the limits of unavoidable manufacturing variations) in the cavity 21.

[0094] It is also possible to perform the procedure according to the Fig. 5 and Fig. 6 using the procedure according to Fig. 4 to connect. Thus, it is conceivable that the gaps 21 between the panels 12a, 12b, 12c and 12d and / or the gaps 52 between the panels 12a, 12b, 12c and 12d and the shell 31 can be connected using the method according to the Fig. 5 and Fig. 6 is filled with the filling material 13 using the press mold 51. Additionally, the spraying or application process can be carried out from the outside according to Fig. 4 for filling pseudo-sutures with filling material 13 are used. Reference symbol list 11 Ball 12a-12d panels 13 Filling material 21 Gap 22 Pseudo suture 23a, 23b Panel side edges 24a, 24b Panel exterior surfaces 25a, 25b beveled webs 26 Surface area of ​​the filled fill material 31 case 41 robot arm 42 nozzle 51 Press mold 52 columns 61 Air intake 62 Inlet for filling material 63 vertical axis 64 horizontal axis

Claims

[1] Ball (11), in particular a football, having: a. a shell with a plurality of panels (12a, 12b, 12c, 12d) on the outside of the shell, wherein at least one panel of the plurality of panels has a pseudoseam (22) which extends over at least part of an outer surface of the panel, wherein b. the panels (12a, 12b, 12c, 12d) are arranged such that at least one gap (21) is created between at least two adjacent panels (12a, 12b), and wherein c. the at least one gap (21) is at least partially filled with a filling material (13), wherein the gap is such that the at least two adjacent panels do not touch in the area of ​​the gap, d. wherein at least one pseudoseam (22) is filled with the filling material. [2] Ball according to claim 1, wherein the filling material fills the gap such that the outside of the shell is completely covered within the gap. [3] Ball according to any of the preceding claims, wherein the filling material comprises polyurethane or silicone. [4] Ball according to one of the preceding claims, wherein the filling material has at least one light element. [5] Ball according to one of the preceding claims, wherein the filling material comprises at least one electronic element. [6] Ball according to any of the preceding claims, wherein the filling material fills the cross-sectional area of ​​the gap to 50% or more. [7] Ball according to any of the preceding claims, wherein the casing is a bladder or a carcass arranged on a bladder. [8] Method for manufacturing a ball (11), in particular a football, comprising the steps: a. Providing a cover (31); b. Providing a large number of panels (12a, 12b, 12c, 12d); c. Arranging the multitude of panels (12a, 12b, 12c, 12d) in a press mold; d. Arranging the plurality of panels (12a, 12b, 12c, 12d) on the shell (31) such that at least one gap (21) is created between at least two adjacent panels (12a, 12b, 12c, 12d); e. Filling at least one gap (21) at least partially with a filling material (13), wherein the filling material is liquid; f. Rotating the press mold so that the filling material is distributed substantially evenly in the at least one cavity (21); and g. Hardening of the liquid filler material. [9] Method according to claim 8, further comprising the step of bringing the panels against the shell by means of the press mold, so that at least one gap is created between the at least two adjacent panels and gaps are created between the panels and the shell. [10] Method according to the preceding claim, further comprising the step of injecting the filling material into the gaps between the panels and the shell. [11] Method for manufacturing a ball (11), in particular a football, comprising the steps: a. Providing a cover (31); b. Providing a large number of panels (12a, 12b, 12c, 12d); c. Arrange the plurality of panels (12a, 12b, 12c, 12d) on the shell (31) such that at least one gap (21) is created between at least two adjacent panels (12a, 12b, 12c, 12d); d. Filling at least one gap (21) at least partially with a filling material (13); wherein the filling material (13) is applied from the outside in liquid form to fill the at least one gap (21), wherein the filling material is applied to the shell by means of a robot arm (41), and e. Hardening of the liquid filler material. [12] Method according to any one of claims 8 to 11, wherein the at least two adjacent panels are arranged such that the gap is such that the at least two adjacent panels do not touch each other. [13] Method according to any one of claims 8 to 12, wherein the filling step is carried out such that the filling material fills the gap in such a way that the outside of the shell is completely covered within the gap. [14] Method according to any one of claims 8 to 13, wherein the filling material is applied by a three-dimensional application technique. [15] Method according to any one of claims 8 to 14, further comprising the step of forming at least one pseudoseam (22) on at least one panel, which extends over at least part of an outer surface of the panel. [16] Method according to the preceding claim, further comprising the step of filling the at least one pseudoseam (22) with the filling material. [17] Method according to claim 8, wherein the step of filling the at least one gap with a filling material is designed such that the filling material enters the gap from the outside of the shell. [18] Method according to any one of claims 8 to 17, wherein the filling material comprises polyurethane or silicone. [19] Method according to any one of claims 8 to 18, wherein the casing is a bladder or a carcass arranged on a bladder. [20] Method according to any one of claims 8 to 19, wherein the step of filling the at least one gap with the filling material comprises adjusting the amount of filling per unit of time to the cross-sectional area of ​​the gap. [21] Method according to the preceding claim, wherein the cross-sectional area of ​​the gap is detected in real time by means of an optical method.

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