Ball and manufacturing method thereof

Abstract

To provide balls, in particular a football, and a method for its manufacture.SOLUTION: A ball comprises particles of an expanded material.SELECTED DRAWING: Figure 1a

Description

[Technical Field]

[0001] The present invention relates to a ball, in particular a soccer ball, and a method for making the same. [Background technology]

[0002] Balls such as soccer balls, basketballs, or children's game balls in different configurations Balls and various methods for their production are known from the prior art.

[0003] For information on materials with good rebound properties, please see the website http: / / www.azom.com / news.aspx?Ne wsID=37360 refers to a new foamed thermoplastic polyurethane material. The site has been tested under ISO 8307 (ball resilience test) and DIN 53512 for approximately It mentions that it exhibits a rebound height of 55%.

[0004] Regarding different ball constructions, a solid ball made from a foam material is a children's game ball. CN100506327C is commercially available as A solid resilient ball is disclosed having a core made from a foam polyurethane material. U.S. Pat. No. 4,943,055A describes a ball with a metal core to increase its weight and an outer layer. and an intermediate layer including a filler material, for example, a polymer such as polyurethane. The company discloses the following:

[0005] U.S. Patent No. 3,508,750A and U.S. Patent No. 8,777,787B2 are ball panels. More specifically, U.S. Pat. No. 3,508,750A discloses a ball structure using a ball. discloses a game ball having a plurality of ball panels bonded to a carcass. Patent No. 8777787B2 is a sports box that may include a casing, a midsole, and a bladder. The patent discloses a ball that is manufactured by assembling a panel element of a casing and a bladder. A mold can be placed therein, and an intermediate layer of polymer foam material can be placed between the bladder and the panel element. In addition, the edges of the panel elements can be heat bonded together to secure the panel elements together. The elements can be joined to form the seams of the casing.

[0006] U.S. Patent No. 5865697A, GB2494131B, U.S. Patent No. 7867115B Further ball configurations are known from U.S. Pat. No. 7,740,551 B2 and U.S. Pat. No. 7,740,551 B2. US Patent No. 5,865,697A discloses a ball in which an intermediate layer having an elastomeric material is attached to an outer layer of the ball. GB discloses a sports ball disposed in a waffle-like arrangement between a ball and a bladder. No. 2,494,131B discloses an inflatable ball having a first half and a second half, Each half includes reinforcing ribs on the inner or outer wall, and one half includes a hole with a valve unit. US Patent No. 7,867,115B2 describes an optical assembly consisting of a power supply and multiple LEDs. The present invention discloses a toy ball having a rib and a spherical skeleton structure including a plurality of segments. In 2004, U.S. Patent No. 7,740,551 B2 discloses an inflatable balloon that includes a structure for receiving electronic components. The patent discloses a bladder for a roller.

[0007] US Patent No. 6,106,419A and WO97 / 17109A1 are used in games The present invention relates to balls for the purpose of playing golf, particularly pressureless balls such as pressureless tennis balls.

[0008] A drawback of some balls known from the prior art is that the process cycle for their manufacture is complex. Also, the surfaces of prior art balls are likely to deteriorate significantly over time. The surfaces of conventional ball panels or the seams between panels can become brittle, e.g. This can cause the ball to lose its shape due to a decrease in tear strength and / or water buildup. Too much of the material in the ball reduces its shape stability and leads to poor physical properties. In addition, a further drawback of known balls is that they may lose elasticity, especially at low temperatures. or the need for repeated expansion to maintain the desired usage properties. do. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] CN100506327C [Patent Document 2] U.S. Patent No. 4,943,055A [Patent Document 3] U.S. Patent No. 3,508,750A [Patent Document 4] U.S. Patent No. 8777787B2 [Patent Document 5] U.S. Patent No. 5,865,697A [Patent Document 6] GB2494131B [Patent Document 7] U.S. Patent No. 7,867,115 B2 [Patent Document 8] U.S. Patent No. 7,740,551 B2 [Patent Document 9] U.S. Patent No. 6,106,419A [Patent Document 10] WO97 / 17109A1 [Patent Document 11] DE102012206094A1 [Patent Document 12] EP2649896A2 [Non-patent literature]

[0010] [Non-Patent Document 1] Website: http: / / www.azom.com / news.aspx?NewsID=37360 Summary of the Invention [Problem to be solved by the invention]

[0011] It is therefore an object of the present invention to avoid or reduce at least some of the disadvantages of the prior art. The object of the present invention is to provide an improved ball, such as a soccer ball, that allows the ball to be played in a variety of ways. It has good elastic properties at both low and high temperatures and has long-lasting properties in terms of both physical properties and appearance. Furthermore, the complexity of ball manufacturing should be minimized. In addition, the weight, surface area, and other specifications are adjusted by the manufacturer to suit the individual requirements of each application. The ball's characteristics are improved in terms of surface texture, aerodynamics, etc. It should be adjustable. [Means for solving the problem]

[0012] Such problems are at least partially solved by the game ball of claim 1. In an embodiment, the ball, particularly the soccer ball, comprises particles of an expanded material.

[0013] The use of particles of foamed material can be advantageous in several ways. First, the Its use can increase the abrasion resistance and tear strength of the ball and especially its surface. Second, balls with such particles can have good elastic properties, and this Elastic properties are (basically) measured at low temperatures, for example, temperatures below 0°C (for example, temperatures between -40°C and 0°C). Even at high temperatures, such as temperatures above 20°C (for example, temperatures between 20°C and 45°C), can also be maintained.

[0014] The foam materials include the following materials: expanded thermoplastic polyurethane (eTPU), expanded polyurethane Polyether block amide (ePEBA), expanded polyamide (ePA), expanded polypropylene Polyethylene (ePP), Expanded Polystyrene (ePS), Expanded Ethylene Vinyl Acetate (eEV A) may contain at least one of the following:

[0015] The particles of such foamed material can be lightweight and have very good elastic properties, The elastic properties can be maintained at both low and high temperatures (e.g., within the temperature ranges mentioned above), The particles are well suited for use in balls according to the present invention. It can exhibit a relatively high energy return following expansion, which allows for particularly good rebound of the ball. The use of particles gives the ball, especially its surface, high tear strength and durability. It can contribute to providing wear resistance.

[0016] Those skilled in the art will appreciate that the individual particles of the ball may contain different mixtures or combinations of such materials. Therefore, the material composition of the individual particles may vary across the ball. or may vary over different regions or portions of the ball. This can be useful when trying to locally influence the ball's properties during play.

[0017] The ball may be made of plastic material, fabric material, metal wire, leather or other additional foam material It may further comprise a non-foaming material.

[0018] The particles may be bonded to one another. The particles may be fused together, particularly at their surfaces. For example, By exposure to heat in the form of (pressurized) steam and / or by exposure to compression and heat Alternatively, the particles may be fused together on the surface.

[0019] High frequency (HF) welding, e.g. radio frequency (RF) welding, and / or infrared (IR) welding Heat may be applied by at least partial RF welding and / or I R welding may be used to bond the particles together. "At least partially" means that such It may also mean that such techniques may be combined with other techniques to bind particles.

[0020] The surfaces of the particles may be fused together using, for example, RF welding.

[0021] Alternatively or additionally, the particles may be attached in a different manner, for example, by the use of adhesives or glues. may be bonded to each other.

[0022] Additionally, the particles may be randomly placed, which allows for specific placement of particles within the manufacturing tool. There is no need to arrange them in a pattern or configuration, which can significantly reduce manufacturing effort. .

[0023] The particles may be arranged in a particular pattern, which may affect a portion of the ball or the entire ball. It may be easier to tailor the properties of the body, for example, by aligning particles in a certain direction. The particles may be arranged in terms of size. Layers of small particles may be interspersed between layers of larger particles. It will also be appreciated that this can be used to adjust the characteristics of the ball.

[0024] A plastic coating and / or plastic foil material is applied to the outward facing surface of the ball. It may be placed.

[0025] Plastic coating or plastic on the outward facing surface of the ball (or part thereof) The black foil material increases the durability, abrasion resistance or tear strength of the ball and especially its outer surface. Also, the plastic coating or plastic foil material can be used to The feel and handling of the ball, e.g. affecting the grip of the wheel or its water repellency, and its aerodynamics In this way, it is also possible to

[0026] The outer surface of the ball and / or the aforementioned plastic coating and / or The plastic foil materials mentioned above may include a textured surface. That's fine.

[0027] Texture favorably affects the feel, handling, and aerodynamics of the ball. For example, if the surface is too smooth, the ball will be difficult to handle. Not only that, but the ball can also wobble considerably in flight.

[0028] In embodiments where the outward facing surface of the ball is textured directly, a plastic coating Alternatively, the plastic foil material may not be necessary. stabilize the texture, improve the appearance and / or protect against wear and other external influences It may be advantageous to add a plastic coating or plastic foil material to provide protection. It could be.

[0029] The ball may include at least a first layer having particles of a foam material. may be provided, in particular as the outer shell of the ball.

[0030] The statement that the first layer comprises particles of foam material does not imply that other portions of the ball comprise particles of foam material. It should be noted that this does not mean that foam particles may not be included. As long as the foam material is not too thick, it may be part of another part of the ball. There may be different foam materials for different particles, and therefore different areas of the ball. It is emphasized that the amount of the oxidized material may vary over a range or area.

[0031] The first layer, which comprises particles of a foam material and is provided as an outer shell, is e.g. It may also be suitable for increasing the durability of the outer shell by increasing its abrasion resistance.

[0032] The ball may include multiple layers, particularly multiple layers having particles of foam material.

[0033] Some or all of the layers may contain particles of a foam material. Some layers may be made of different materials, for example, non-foamed plastic materials, or fabric materials, metal wires, etc. This allows for different physical and mechanical properties of the ball to be separately controlled. This allows for impact at various depths to be tailored to the manufacturing process or desired needs of the end user. and increased possibilities to adjust the ball to suit requirements.

[0034] the thickness of the layer and / or the composition of the material of the layer, in particular the composition of the foam material of the particles, and / or At least one process parameter for the production of the layer is It may vary between.

[0035] That is, the parameters mentioned above (thickness, material composition of the (foam) material, process parameters) ) may vary within a given layer and / or between different layers.

[0036] In this way, for example, tear strength, rebound properties, etc., can be adjusted within one layer and / or between different layers. Energy return rate, density, etc. can be separately adjusted during manufacturing as desired.

[0037] The first layer has a thickness in the range of 0.5 mm to 10 mm, preferably in the range of 1 mm to 5 mm. It can have.

[0038] For example, if the first layer is provided as the outer shell of the ball, the thickness range However, it is a favorable compromise between sufficient stability on the one hand and minimizing the weight and thickness of the material on the other hand. The resulting desired properties for each ball are This compromise can be adjusted accordingly. Thus, in embodiments, such thicknesses and providing a ball that is completely (or at least primarily) constituted by an outer shell having a It is possible.

[0039] The thickness of the first layer may vary. The first layer may have different thicknesses in different areas. The thickness of the first layer may vary gradually between thicker and thinner regions without local For example, the first layer may include one or more reinforcing ridges or struts, e.g. If desired, the inner surface of the ball may contain a material such as a fluorine-containing compound, thereby enhancing the shape stability of the ball.

[0040] By varying the thickness of the first layer, the final properties of the ball can be tailored to the desired application. It is also possible to use thicker areas to improve the shape and stability of the ball. Alternatively, the rebound or flight characteristics of the ball can be modified.

[0041] The first layer may include a plurality of ball panels having particles of a foam material. If the ball panel includes multiple layers, some or all of the additional layers may also be incorporated into the ball panel, especially ball panels with particles. A control panel may be included.

[0042] Multiple ball panels can be used to provide the first layer, allowing for multiple This allows for the production of balls in series production. Individual ball panels can be manufactured in such a mass production This is because it is suitable for automated handling, for example. They can be mechanically connected, for example, glued or sewn together. However, the foam particles are directly bonded to each other to connect the ball panels. It is also possible to remove particles on the contact surfaces of two abutting ball panels, for example by direct welding. As a result, the use of additional materials such as adhesives or seams may be reduced or avoided. and a particularly durable and resistant connection can be achieved.

[0043] Individual ball panels can be welded together, for example, using RF and / or IR welding techniques. Such techniques may be used to fabricate panels together where they abut one another. For example, RF fusion techniques may be used in conjunction with ball panels as described herein. They may also be used in combination.

[0044] The ball is constructed by assembling three-dimensional preformed ball panels, at least It may be partially manufacturable.

[0045] The use of three-dimensional pre-formed ball panels greatly simplifies panel assembly. It is possible to simplify the assembly process by eliminating the need to bend or deform the ball panel during assembly. This is because only a small amount of flat ball panels are needed at first. Material distortion that can occur when it must be "curved" into a three-dimensional shape during assembly This can also help to avoid the automation of production processes. It is also possible to do so.

[0046] The ball may include at least one cavity, the first layer being disposed around the cavity. If there are further layers, they are arranged around the cavity, e.g. It may be disposed between the layer and the cavity.

[0047] In embodiments having one or more layers and a cavity, the first layer (and optionally It is essential that the layer (additional layer due to the Rather, the first layer being disposed around the cavity is not an essential feature of other embodiments of the present invention. As in the case of the ball, the first layer moves inward toward the center of the ball. It simply means that the ball is not completely solid. Like the (elastic) support structures described below, they can extend into the cavity. By having such a property, a relatively lightweight ball can be provided.

[0048] A first layer may be placed on the ball carcass surrounding the cavity. In this case, such a layer may be disposed, for example, between the carcass and the first layer. may be sandwiched between the two layers.

[0049] The ball carcass serves to facilitate the manufacture of the first layer (or layers). This is because the first layer is made up of multiple separate components, e.g., multiple boards as previously mentioned. This is especially true when the carcass is assembled from a single panel. It is also possible to increase

[0050] The ball carcass may include an inflatable bladder.

[0051] The inflatable bladder surrounds the cavity in an essentially gas-impermeable manner. With an inflatable bladder, it is possible to inflate the bladder or release gas from the bladder. Ejection may further allow adjustment of the ball's properties during use. The valve may include a valve unit through which a cavity within the inflatable bladder may be opened. The tee can be filled or emptied.

[0052] The cavity may in particular be filled with at least one gas above atmospheric pressure.

[0053] A closed surface that is essentially gas impermeable to retain pressurized gas within the cavity. The cavity should be enclosed. For this reason, the scope of the invention encompasses different possibilities. For example, the first layer may comprise a closed surface that is essentially gas impermeable. Alternatively, a closing surface that retains gas within the cavity may be disposed between the first layer and the cavity. Such a closing surface may be disposed between the first layer and the cavity to retain the gas. Examples are ball carcasses and especially inflatable bladders. Filling the ball with one or more gases such as Filling the cavity with gas above atmospheric pressure can help the ball The adhesive may further play a role in varying and controlling the elasticity and rebound properties of the material.

[0054] The ball of the present invention may include a support structure, particularly a resilient support structure, that includes particles of foam material. Cut.

[0055] Such a support structure can increase the stability of the ball. It plays a role in influencing the properties of the ball, for example the elasticity of the ball and its rebound characteristics. This is because the elastic support structure contains particles of a foam material, which allows for good elasticity of the particles. This is especially true since sexual characteristics can be transmitted to supporting structures.

[0056] Such support structures represent an independent aspect of the present invention and therefore may be used in conjunction with conventional ball panels. It is noted that it is also possible to use

[0057] In general, those skilled in the art will appreciate that the different aspects, embodiments, and design options described herein are readily apparent to those skilled in the art. The elements may be combined in any way (as long as it is physically possible), and therefore the present invention You will understand that this represents the independent nature of the Ming.

[0058] As previously mentioned, the ball may include a cavity, and the support structure may be positioned within the cavity. At least one of the extending wall, the bar extending within the cavity, and the inner shell extending within the cavity. It can also contain one of the following:

[0059] Thus, in such embodiments of the invention, the ball does not include a completely solid core. However, to improve the dimensional stability of the ball, elements of the support structure may extend within the cavity. Furthermore, the elastic properties of the ball are further enhanced by the (elastic) support structure. may be affected.

[0060] The support structure may include at least one spherical inner shell.

[0061] To provide a ball having a configuration according to the "onion skin principle", one or more The spherical inner shells may be connected to each other and to the outer shell by bars or walls. By using a spherical shell, imbalance of the ball is essentially avoided and the ball is approximately isotropic. The object has a property of invariance, i.e., a property that does not change with any kind of rotation.

[0062] The support structure may include at least one region having a repeating conformation. That is, the support structure may include repeating units or unit cells, and several of such unit cells may be The stubs are positioned adjacent to one another to form at least one region of the support structure. Each of the several unit cells may have the same three-dimensional shape, but may vary in size. However, the support structure may have at least one region with a periodic three-dimensional structure. In this case, the unit cells arranged adjacent to each other may have the same three-dimensional shape. Not only do they have the same shape, but they also have the same size.

[0063] The unit cell may be a honeycomb. The unit cell may be a sphere. The unit cell may be a cube. The unit cell may be a rectangular prism. The unit cell may be a triangular prism. The unit cell may be an octagonal prism. The unit cell may be a tetrahedron. The unit cell may be a tetrahedron. The unit cell may be a pyramid. The unit cell may be a cylinder. The unit cell may be a cone. Those skilled in the art will recognize that several other alternative unit cells are possible to achieve the same desired effect. You will understand that.

[0064] The support structure may be more completely provided by repeating / periodic structures. Only one or more subregions of the structure may contain such repeating / periodic conformations For example, the support structure may include an inner spherical shell, and the support structure may include an inner shell and an outer shell. As used herein, the repeating / periodic configuration may be further provided as a repeating / periodic configuration between The body structure, on the other hand, is characterized by the fact that the supporting structures (or regions with repeating / periodic conformations) are perpendicular to the cross-section. The ball is seen in cross section in a tubular configuration in a variety of directions. The connecting piece may include a plurality of parallel extending tubes, with the tubes extending perpendicular to their longitudinal axes. The cross section shows a repeating / periodic conformation, which can be used to tailor the properties of the resulting ball. For example, the tubes may be arranged only longitudinally. The difference in orientation can improve the shape stability of the ball or improve the rebound characteristics or flight of the ball. The properties can be modified.

[0065] The support structure has a rotation angle α of symmetry about an axis of symmetry extending through the center of the ball such that: It may have at least one rotational symmetry.

[0066] An object rotates at a certain angle around an axis if the object "looks the same" before and after the rotation. In other words, an object has rotational symmetry with respect to a rotation. shows rotational symmetry.

[0067] Applying the above statement about the (at least one) rotational symmetry of the support structure, this is the condition where the support structure "appears identical" before and after a rotation of angle α around the axis of symmetry passing through the center of the ball. It means "to be."

[0068] If the support structure has at least one rotational symmetry, the support structure will cause the ball to become significantly unstable. Such imbalance can adversely affect the ball's properties. Generally, it is advantageous for the support structure to have a high degree of symmetry. The support structure contains only a limited degree of symmetry to intentionally create an imbalance in the ball. In some cases it may be desirable to have no symmetry, or even no symmetry at all. A ball used in bowling or bowls to allow the ball to curve along a course This may be desirable for the

[0069] The symmetry angle α can be one of 120°, 90°, 72°, 60°, or a continuous rotation. It is also possible.

[0070] Such three-, four-, five-, six-sided, or continuous rotational symmetry is designed in such a way that The supporting structure on which it is placed has isotropic properties, i.e. properties that do not change under rotation around an axis of symmetry. Advantageously, this may result in a ball that is at least approximately symmetrical. The larger the number of faces, i.e., the smaller the symmetry angle α, the higher the isotropy. However, this increases manufacturing costs, so the design of the support structure requires a symmetric angle. The appropriate selection of the variability of the ball in terms of rotation on the one hand and low manufacturing costs on the other hand. It can be a compromise between cost and

[0071] The first layer and / or the support structure may define at least one chamber. At least one chamber may be filled with at least one gas at a pressure higher than atmospheric pressure. good.

[0072] Such a chamber may be defined by and located within the first layer itself. This can also help to keep the weight low. In this case, the chamber may be located within another layer of the ball, and the chamber may span several layers. Further, the chamber may be defined by a support structure, and the support structure may further extend therethrough. For example, the support structure of the present invention may be used in conjunction with a conventional ball panel. Finally, the support structure is attached to the first layer (or It is also possible to define a chamber where the layer contacts one or more other layers.

[0073] Similar to an inflatable bladder, a chamber filled with one or more gases (above atmospheric pressure) The ball's elastic properties, especially its rebound properties, are affected and controlled by the This control can be simplified because the support structure may further include complex three-dimensional geometries. It may even be possible to go to a more detailed level than is possible with a standard inflatable bladder.

[0074] Adding a chamber to a thicker layer of a hollow ball, for example, reduces the ball's stiffness and reduces rebound. A larger chamber will result in a weaker ball than a smaller chamber. When comparing the same chamber volume, the spherical chamber It is possible to produce a stiffer ball than other shapes. The smaller the chamber, the less deflection and Because there is "more material" to bear the load, stiffness and / or rebound may be higher.

[0075] Spherical chambers may also be stiffer and / or more flexible than chambers having, for example, rectangular cross sections. Buckling and bending can occur during deformation, reducing rebound efficiency. Chambers with pointed edges (pyramids, very flat rectangles, eight-sided The body of the ball and other components can create stress concentrations that can reduce the durability of the ball.

[0076] Radially around the ball (in and out from the center), the chambers can be "long" or "short" in length. In the polar and / or azimuthal directions (i.e., toward the surface), the chamber is "wide" It can be "thin" or "large" ("may take up a large portion" or a small portion). If the bar is very wide and long, the ball will have inconsistent rebound in height and direction. In the case of a very wide (and short) chamber, the ball may have soft spots and This can cause the chamber to collapse.

[0077] Adding and removing chambers or placing chambers at different distances from the center of the ball This can affect the angular or rotational inertia of the ball. For example, if the chamber is larger and / or closer to the outside of the ball, the rotational inertia The spin rate of a ball in flight with low rotational inertia is lower than that of a ball with higher rotational inertia. The spin rate of a soccer ball decreases faster than that of a ball with a high spin rate. affects aerodynamic characteristics, including but not limited to drag and deflection / curve characteristics. The change in rotational inertia can also be significant in kicking / controlling the ball.

[0078] Compared to conventional shell balls, e.g., chambered or non-chambered, Balls of the present invention with a thick first layer have more mass toward the geometric center of the ball. Because it moves, it has a lower rotational inertia for the same weight, resulting in a decrease in spin rate. Reducing the spin rate can improve aerodynamic performance in the deflected state. This is because a small amount can delay the onset of the inverse Magnus effect. As a result, the ball may travel less straight towards the end of its flight.

[0079] Additionally, the size and location of the chambers can be modified to eliminate any potential imbalances that may cause the ball to become unbalanced. Any valve, panel, or other mass may be balanced.

[0080] The walls of the chamber may be essentially gas impermeable.

[0081] The chamber is essentially gas-impermeable, allowing one or more gases at pressures above atmospheric pressure to enter the chamber. The chamber can be filled to a constant pressure and maintained at this pressure. Refilling of the barbs can be avoided.

[0082] At least a portion of the first layer (or other layer adjacent to the support structure) and at least a portion of the support structure The two parts may be manufactured together as a single unit.

[0083] By integrally manufacturing at least a portion of the first layer and a portion of the support structure as a unitary part, This allows a particularly tight and resistant connection to be achieved. and forming a chamber defined by the first layer and the support structure that can be filled with one or more gases. It may be advantageous to provide a foamed structure in which both the first layer and the support structure contain particles of foam material. It may be advantageous to be able to bond, e.g., weld, the surfaces of the particles directly to one another. where the support structure contacts the first layer to create an integral connection.

[0084] The ball may be a solid ball.

[0085] A solid ball may allow for easier and faster production and may eliminate the need for ball expansion. By using particles of foam material for the construction of the ball, the ball still The ball can, of course, contain particles in addition to the particles themselves to provide the desired elasticity and rebound characteristics. It may also include a material.

[0086] The ball may, for example, include a core of a non-foam material.

[0087] Such a non-foam core may be used to adjust the weight of the ball, improve its stability, It can serve several purposes, such as influencing elasticity.

[0088] The ball may not include an inflatable bladder.

[0089] For example, the various possibilities for designing the support structure described herein may still allow for desired A ball without an inflatable bladder may be provided having elastic properties of This eliminates the need for shaving and provides a ball that permanently exhibits the desired characteristics.

[0090] A further aspect of the invention relates to a method for making a ball according to the invention.

[0091] The different manufacturing options are explained in more detail below. Select from among these options that are most suitable for the manufacture of a particular embodiment of the ball, and / or or combinations thereof. Thus, exemplary embodiments of the methods of the present invention are Only applications are briefly mentioned below, but such examples are used to limit the scope of application of the method. It should not be interpreted as a thing.

[0092] The method may include bonding particles of the foam material using radio frequency (HF) radiation. The method may involve, for example, using radio frequency (RF) welding and / or infrared (IR) welding to form the foam. The method may include bonding particles of material together. In particular, the method may involve bonding surfaces of the particles together using RF welding. The method may include fusing the

[0093] Embodiments using different electromagnetic radiation, or electromagnetic fields in general, for particle binding are also included within the scope of the present invention. This is included in the method.

[0094] The method includes loading particles of foam material into a rotating mold and rotating at least a portion of the ball. The method can further include continuously manufacturing multiple layers by rotational molding. may include:

[0095] In this way, a solid ball or a ball with one or several layers and optionally a central core can be produced. Balls can be manufactured that contain cavities.

[0096] The method includes forming a foamed material containing particles of foam material and assembled to at least partially form a ball. This may include manufacturing a plurality of ball panels.

[0097] The advantages of using ball panels in the manufacture of balls have been discussed above.

[0098] The manufacture of individual ball panels involves the steps of loading particles of foam material into a mold and then transferring the particles to the mold. and b. compression molding in a mold.

[0099] Compression molding (at least partially) laser variothermal The Variotherm method involves placing a It has heating and cooling channels, which allows the surface of the mold to be heated and cooled quickly. The range of heating and cooling possible is 100 Kelvin in 20 seconds. .

[0100] For example, by using such a variotherm method, the individual ball panels can be The process cycle time for the production of the panel is less than 5 minutes, preferably less than 3 minutes. It is possible.

[0101] This is advantageous as it significantly reduces the debonding (cycle) time for manufacturing the part. do.

[0102] Bonding particles using RF fusion or some other method that uses electromagnetic radiation One or more panels may be produced by such a method, or such a method may be or multiple panels. A method may be used to connect the panels (or at least some of them) to one another.

[0103] The manufacturing of ball panels involves forming a first foil material into a mold before loading the particles into the mold. Forming the first foil material in the mold may further include forming the first foil material This may include vacuum forming / deep drawing.

[0104] Alternatively, the first foil material may be applied after the particle panels have been formed. and compressing the particles to form a panel free of the first foil material; Only after compression molding can the first foil material be applied.

[0105] The first foil material may be located on the outside of the panels of the assembled ball, thus The foil can affect the appearance and performance of the panel, for example. The coating can be used to increase the wear resistance of the ball or can serve decorative purposes.

[0106] Compression molding is carried out at a temperature of 80°C to 200°C, preferably 100°C to 180°C, particularly preferably Preferably, the reaction can be carried out at a temperature of 135°C to 145°C.

[0107] The compression molding temperature is at or near the temperature at which the foam material in the particles begins to melt. This allows the surfaces of the particles to be bonded together without damaging the internal cell structure of the particles. It may be possible to combine

[0108] In addition to the many advantages mentioned above, a further important advantage of using foam particles is that they A process cycle for the production of ball panels and therefore balls using such particles is described. This allows for increased production efficiency and output. do.

[0109] The method of manufacturing the ball comprises applying a second foil material to part or all of the panel, in particular The method may further include vacuum forming a second foil material over some or all of the panel.

[0110] A second foil material can be applied in addition to the first foil material, thereby forming the panel from a foil material Alternatively or additionally, it may be possible to completely surround the device with a foil or coating. A further layer of foil is applied to the panel surface or onto the foil / coating to form a multi-layer film. Different layers of the film may have different properties. The multilayer film may include an abrasion layer. The multilayer film may include a UV-resistant layer. It may also include layers to modify the optical properties of the surface.

[0111] Rather than applying a foil layer during the processing of the panel during molding, the foam particles are formed into the panel. It is also possible to apply it as a spray coating after the coating.

[0112] The foamed material used in the above-mentioned method may be the following material: foamed thermoplastic polyurethane. Tan (eTPU), Expanded Polyether Block Amide (ePEBA), Expanded Polyamide ( ePA), Expanded Polypropylene (ePP), Expanded Polystyrene (ePS), Expanded Ethylene The polymer may include at least one of: eVa;

[0113] As previously mentioned, the method involves applying the spray material to, for example, the outward facing surface of the ball, particularly the ball panel. The invention may further include applying the coating to some or all of the exterior surfaces of the coating.

[0114] Such sprayed materials can affect the appearance and performance of the ball. For example, sprayed materials may be used to decorate the ball, and the sprayed materials may be water-resistant. Often, the sprayed material may enhance the grip or abrasion resistance of the ball surface, or This may beneficially affect the aerodynamics of the wheel.

[0115] Possible embodiments of the invention are further described below in detail with reference to the following drawings: We will explain further. [Brief explanation of the drawings]

[0116] [Figure 1a] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1b] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1c] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1d] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1e] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1f] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1g] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1h] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 1i] 1 is a cross-sectional view of a possible embodiment of a ball according to the present invention; [Figure 2a] 10A-10C illustrate further possible embodiments of balls according to the present invention having multiple ball panels. [Figure 2b] 10A-10C illustrate further possible embodiments of balls according to the present invention having multiple ball panels. [Figure 2c] 10A-10C illustrate further possible embodiments of balls according to the present invention having multiple ball panels. [Figure 2d] 10A-10C illustrate further possible embodiments of balls according to the present invention having multiple ball panels. [Figure 2e] 10A-10C illustrate further possible embodiments of balls according to the present invention having multiple ball panels. [Figure 3a]10A-10C are cross-sectional views of further possible embodiments of balls according to the present invention having support structures. [Figure 3b] 10A-10C are cross-sectional views of further possible embodiments of balls according to the present invention having support structures. [Figure 3c] 10A-10C are cross-sectional views of further possible embodiments of balls according to the present invention having support structures. [Figure 4a] 1A-1C illustrate an embodiment of a method for manufacturing a ball of the present invention using a rotating mold. [Figure 4b] 1A-1C illustrate an embodiment of a method for manufacturing a ball of the present invention using a rotating mold. [Figure 5a] 1A-1C illustrate an embodiment of a method for manufacturing a ball of the present invention, including fabricating a ball panel. [Figure 5b] 1A-1C illustrate an embodiment of a method for manufacturing a ball of the present invention, including fabricating a ball panel. DETAILED DESCRIPTION OF THE INVENTION

[0117] Possible embodiments of the present invention are described in detail below, primarily in relation to soccer balls. However, it should be emphasized that the present invention is not limited to these embodiments. Inventions include basketballs, footballs, tennis balls, volleyballs, Balls, baseballs, rugby balls, golf balls, bowling balls, toy balls, etc. It will be obvious to those skilled in the art that the invention can be easily adapted to any other type of ball.

[0118] Only some individual embodiments of the invention will be described in more detail below. and all possible combinations and permutations of the different design options provided by the present invention. It should also be noted that the present invention does not explicitly state that the specific embodiments described below are intended to be illustrative and not restrictive. The design options described in connection with the embodiments may be further modified and different embodiments may be implemented within the scope of the present invention. It will be clear to those skilled in the art that the various features may be combined with one another in a variety of ways. To avoid repetition, the following detailed explanations are omitted. See the description of the predicate.

[0119] Throughout the following description, the same reference numerals are used to denote functionally similar or equivalent parts. However, reference to a particular component made in the context of a particular embodiment does not necessarily imply an equivalent description of the component in other embodiments. It also relates to parts.

[0120] 1a-1i, 2a-2e, and 3a-3c show possible implementations of ball 100. 1 shows an embodiment. Ball 100 may be, for example, a soccer ball.

[0121] Ball 100 includes particles of a foam material. The particles may be randomly arranged. The materials are: Expanded Thermoplastic Polyurethane (eTPU), Expanded Polyester ePEBA, expanded polyamide (ePA), expanded polypropylene (e PP), expanded polystyrene (ePS), and expanded ethylene vinyl acetate (eEVA ) may be included.

[0122] It is understood that combinations of such materials may be used as particles within a given ball, i.e. It will be apparent to those skilled in the art that it is also possible that the material composition of the particles may vary across the ball. It would be.

[0123] For example, different layers, sectors, or regions of eTPU and ePEBA may be incorporated into the ball of the present invention. The different layers and Further details regarding possible configurations of the balls of the present invention, including the support structure, are provided below. The materials disclosed and described above may be used in such configurations in a variety of ways within the scope of the present invention. and may be combined.

[0124] Additionally, the ball 100 may be made of a non-foamed plastic material, a foamed plastic (e.g., Two-component polyurethane foam with a continuous uniform structure), leather, rubber, metal wire, It may also include additional materials such as foil.

[0125] The particles of the foam material may be bonded to one another, for example by fusing the particles of the foam material together at their surfaces. The particle surfaces can be fused by applying thermal energy. The process can be carried out, for example, by exposing the particles to pressurized steam in a mold and / or by using a variotherm compound. By using a mold and / or using radio frequency (HF) or IR welding techniques This can be achieved by:

[0126] For example, particles may be bonded using radio frequency (RF) and / or IR welding techniques. The surfaces of the particles may be fused together using, for example, RF fusion. Other types of electromagnetic radiation, For example, radiation from different ranges of the electromagnetic spectrum may be used.

[0127] Alternatively or additionally, an adhesive may be used to bond the particles together. The details of the production are described below.

[0128] 1a-1i are cross-sections through the center of an embodiment of ball 100 of the present invention.

[0129] In the embodiment shown in Figure 1f, the ball 100 is a solid ball 100. Ball 100 may be constructed entirely from particles of foam material, or may contain additional materials. For example, a plastic coating or A black foil material may be placed on the outward facing surface 101 of the ball 100. This coating is achieved by spraying the desired plastic coating / foil onto surface 101. Alternatively or additionally, the outward facing surface 101 may be coated with a coating such as known in the art. In addition, in some embodiments, the outer surface of the surface may be covered with different sprayed materials. The surface 101 may include a textured surface. The outward facing surface 101 is only locally textured. and / or the texture pattern or design may vary locally. Additionally or alternatively, plastic coatings or foils may also be textured. It is also possible to apply this texture only locally. The foil / coating can be textured with respect to the texturing of the outer surface 101. For example, the texture of the coating may overlap the texture of the outward facing surface 101, or The texture of the coating covers the untextured areas of the outward facing surface 101. In this context, the outer surface 101 of the ball 100 may be made of plastic. If no coating, plastic foil material or spray material is applied, the ball may break during use. It should be understood that this is the surface of the roller 100 that comes into contact with the surrounding environment.

[0130] FIG. 1g shows another embodiment of a solid ball 100. Here, the ball 100 has a plurality of The ball includes layers 110, 180, 181, and 182. The first layer 110 is the outer shell of the ball. 100. The first layer 110 comprises particles of foam material. The outer surface 101 of the ball 100 is made of a first foam material. The outer surface 111 of the layer 110 is provided by the additional layers 180, 181, and 182. Here, it is the inner layer, which may also contain particles of foam material. 82 is the same foam material, at least one mechanical between layers 180, 181, and 182 The layers 180, 181, and 182 are made of foamed materials with varying densities. At least one of the layers 180, 181, and 182 may be foamed differently from the other layers. At least one of layers 180, 181, or 182 (and In principle, the first layer 110 may also be a combination of foamed and non-foamed materials. At least one of 80, 181 or 182 (and in principle also the first layer 110) It may also be made of a non-foam material.

[0131] To affect the properties of ball 100, different parameters may be applied to multiple layers 110, 111. 80, 181, and 182. Examples of such parameters include the thickness of layers 110, 180, 181, and 182; 180, 181, and 182, and in particular the material composition of layers 110, 180, 181, and 18 2, or the material composition of the particles in each layer 110, 180, 181, and 182. At least one process parameter used in the manufacturing process is included. within a given layer 110, 180, 181, or 182 and / or between two of these layers. It can be varied between the above.

[0132] As an example, different layers of eTPU and ePEBA may be layers 110, 180, 181 and May be used for / or 182.

[0133] In the embodiment of ball 100 shown in FIG. 1g, the ball further includes core 190. Core 1 90 may be constructed from, for example, a foam material, which may be used to secure the other layers 110, 18 0, 181, and 182. Alternatively, core 190 may be made of a non-foamed material.

[0134] The embodiment of ball 100 shown in FIGS. 1a-1e and 1h-1i is made of particles of a foam material. The ball 10 shown in FIGS. 1a-1e and 1h-1i includes a first layer 110 containing a child. In this embodiment, a first layer 110 is provided as the outer shell 100 of the ball.

[0135] In an embodiment of ball 100 of the present invention, first layer 110 may be, for example, up to 50 mm thick. The thickness is in particular in the range of 0.5 mm to 10 mm, or even 1 mm to 5 mm. The thickness of the first layer 110 may vary across the first layer 110. , i.e., the thickness may not be constant across the layer. The thickness of the first layer 110 may be The transition between the thicker and thinner regions may be gradual or localized. In addition, one or more reinforcing ridges or struts may be configured on the inner surface of the layer, e.g. Additionally, the thickness of first layer 110 may be varied to increase the shape stability of ball 100 .

[0136] As shown in Figures 1d and 1e, the first layer 110 is placed on the ball carcass 130. It is also possible to

[0137] As shown in FIGS. 1a, 1c-1d, and 1g-1i, the first layer 110 is 1d)。 Also, the valve unit 135 may include a closing surface (excluding the hole of the valve unit 135, see FIG. 1d).

[0138] On the other hand, as shown in Figures 1b and 1e, the surface of the first layer 110 may be formed with one or more It is also possible for the first layer 11 to include holes or gaps 115, i.e., no closed surfaces. 0 may be a connecting surface where the holes 115 are located. The connecting surface moves along the surface, and there is no need to "jump" over any gaps, so that from any point on the surface It is a surface that extends to any other point on the surface.

[0139] However, the first layer 110 may be made up of several layers separated from each other by gaps 115. It is also possible to include distinct surface areas. For example, in Figures 1b and 1e, the ball 100 Even with a gap 115 running along the equator and separating the first layer 110 into a northern hemisphere and a southern hemisphere In such a case, the distinct surface areas of the first layer 110 may be fixed in place. However, the support structure 15 shown in FIGS. 3a-3c may be provided by a ball carcass 130. 0 (for simplicity, as will be explained further below). Each of the regions again contains one or more holes 115. In the example of the Northern and Southern Hemispheres, for example, there is hole 115 at the North Pole of the Northern Hemisphere and hole 116 at the South Pole of the Southern Hemisphere. There may be 15.

[0140] In both cases, the inner surface of first layer 110 separates first layer 110 from the inside of ball 100. A conceptual surface 112 can be defined that cuts through the surface. For ease of reference, the surface 112 will be referred to as a "surface The partition surface 112 is referred to as a "cut surface 112." It can be considered as a surface that protrudes around the inner surface of the extending first layer 110. 112 may be considered a closed surface.

[0141] In the embodiment shown in FIGS. 1a-1e and 1h-1i, the ball 100 has a separation surface 112, there is at least one cavity within the spatial region delimited or bounded by The partition plane 112 is merely a conceptual plane used here for purposes of explanation. I will mention that again.

[0142] The cavity 120 does not have to be directly adjacent to the first layer 110. An example of such a case is In the embodiment of ball 100 shown in FIG. 1h, as described above with reference to FIG. 1g, The ball includes multiple layers 110, 180, 181, and 182. In the example shown in FIG. Ball 100 does not have a solid core, but instead contains a cavity 120 in its center. In this case, the cavity 120 is not directly adjacent to the first layer 110, but instead However, the inner surface of the first layer 110 is still adjacent to the partition surface 182. 12, with a cavity 120 bounded or bounded by a delimiting surface 112. It is emphasized that the image is located within a defined spatial region.

[0143] Additionally, cavity 120 is provided in the embodiment of ball 100 shown in FIGS. 1d and 1e. 110. In this case, the first layer 110 is not directly adjacent to the ball carcass. The carcass 130 is attached to the tire 130. The carcass 130 may have an inflatable tire 130 on its inner surface. The carcass 130 may include a bladder 131, or the carcass 130 may include such an inflatable bladder 131. However, the ball carcass 130 may be used without an inflatable bladder. If ball 100 includes multiple layers 110, 180, 181, 182, the ball The lubricant may be located inside the innermost layer 182, for example, or may be located between two of the layers. It may be placed.

[0144] In the embodiment shown in FIGS. 1d-1e, a ball carcass 130 and an inflatable bladder 131 are It surrounds the cavity 120, which is directly adjacent to the inside of the bladder 131. The ball 100 is connected to the valve unit 131 to allow the ball 100 to expand or contract. The valve unit 135 may further include a valve seat 135 connected to the bladder 131. , the ball carcass 130 (if there is a separate carcass) and the outer shell 110 (and Possibly protruding through further existing layers 180, 181, 182) of ball 100 do.

[0145] First layer 110 and / or ball carcass 130 and / or inflatable bladder 13 If 1 includes the closing surface (excluding the hole of the valve unit 135), then one or Multiple gases can be filled and the gases can be delivered to the cavity 120 for a significant period of time. Examples of gases that can be filled into the cavity include air, nitrogen, or The cavity 120 is filled with one or more gases at pressures higher than atmospheric pressure. To adjust the deformation characteristics of the ball 100, the cavity 120 may be filled with, for example, Filled with one or more gases at pressures of 1 bar, 2 bar, 3 bar, 5 bar, etc. A wide range of inert gases can be used to fill the cavity, and for a given It will be apparent to one skilled in the art that the examples given are merely two of the most commonly used gases. To increase the time that the gas is retained in the cavity, the closing surface of the first layer 110, the ball The lumen 130 and / or bladder 131 are essentially permeable to one or more gases. In this case, essentially, the selected materials and manufacturing methods can be designed so as not to exceed the specified limits. This means as much as the manufacturing process allows.

[0146] In this regard, it is within the scope of the present invention to provide ball 100 having ball carcass 130 and / or or inflatable bladder 131, and yet can be held in place by a ball under pressure. Note that one or more gases may be filled.

[0147] As shown in FIG. 1c, the first layer 110 itself contains one or more chambers 160. These chambers 160 may contain a gas such as air or nitrogen at atmospheric pressure. In consideration of this possibility, the maximum pressure is basically one or more gases. Alternatively, the walls of the chamber 160 may be made impermeable to multiple gases.

[0148] Additionally, as shown in FIG. 1i, which illustrates a modification of the embodiment shown in FIG. 1c, chamber 160 may be configured differently. In particular, the shape and / or configuration of the chamber 160 may be and / or configurations may vary within a given ball 100 even if not explicitly shown herein. .

[0149] The shape and / or configuration of a given chamber 160 can be modified to affect the properties of the ball 100. For example, a more rectangular (or angular) shape, as shown in Figure 1c, may be used. In the case of a spherical chamber 160, a ball 1 having a spherical chamber 160 as shown in FIG. 00, the ball 100 may have lower resilience characteristics. The more spherical the ball 100, the less buckling and bending that occurs when the ball 100 undergoes deformation. Furthermore, again, the size and dimensions of a given chamber 160 can be modified to , which may affect the behavior of ball 100. The size of chamber 160 is determined as follows: , i.e., the smaller the cavity, the greater the rebound of ball 100. 00. Furthermore, the rebound or flight behavior of the ball 100 can be affected. The chamber 160 may be configured and designed to have an effect. The position of the ball 160 may be changed to, for example, produce a ball 100 with a modified flight, i.e., a less The ball 100 is deflected in a direction defined by the area of ​​the ball 100 having the small chamber 160. or providing a ball 100 with unpredictable rebound. Furthermore, it is possible to balance other masses of the ball 100, such as the mass of the valve 135. The chamber 160 may be arranged so that the

[0150] Alternatively or additionally, in the embodiments shown in FIGS. 1a to 1e and 1g to 1i The outer surface 101 of the ball 100 provided by the outer surface 111 of the first layer 110 is The outward facing surface 101 may be textured only locally, and The pattern or design of the texture and / or the surface may vary locally. This may, for example, improve the feel and handling or aerodynamics of ball 100. can.

[0151] Alternatively or additionally, plastic coatings and / or plastic foil materials may be arranged on the outwardly facing surface 101 or a partial region thereof. The stick coating or foil may also include a textured surface. It is also possible here to apply the foil / coating only locally to the outer surface 1. 101, e.g., the texture below the outward-facing surface 101. to protect the surface from abrasion, for example, or to ensure that the texture of the coating 101 textures to highlight them or coating textures It is further possible for the surface to cover the untextured areas of the outward facing surface 101. The plastic coating and / or plastic foil material may modify the appearance of the ball 100. This can also serve the purpose of correcting the ball 100, making the ball more water repellent, or Plastic coatings can improve the feel or aerodynamics of your Lexus 100. may be applied, for example, by spraying onto the material.

[0152] An example of such a foil or coating is the "outer" portion of the embodiment of ball 100 shown in FIG. 1i. The cortex is indicated by 170.

[0153] 2a-2e show an embodiment of a soccer ball 100, in which the ball 100 It is again important to remember that the present invention applies to more than just soccer balls. As emphasized by the continued use of the same reference numerals, FIGS. The above discussion regarding embodiment 1i also applies here. For simplicity, Figs. Only a few specific features of the embodiment shown in 2e are described below.

[0154] The embodiment of ball 100 shown in Figures 2a-2e includes a first The first layer 110 includes particles of a foam material. These are listed at the beginning of the detailed description.

[0155] In the embodiment shown in Figures 2a-2d, the first layer 110 is disposed on the ball carcass 130. The ball carcass 130 may be provided, for example, as an inflatable bladder. , or may include such a bladder, for example on its interior surface.

[0156] The ball carcass 130 can surround the cavity. , which surrounds the cavity in an essentially air or gas impermeable manner, The gas or gases in the cavity are at pressures above atmospheric pressure. The valve unit may be attached to the ball 100 to allow for expansion or contraction. It may also be provided in.

[0157] However, in some cases, as exemplified by the embodiment shown in FIG. 2e, The core 130 may be absent. The outer shell 110 may be essentially impermeable to air or gas. When the carcass is manufactured to form a closed surface surrounding the cavity in a simple manner, 30 or bladder without the need for a gas or gases to be pumped into the cavity above atmospheric pressure. can be maintained high.

[0158] The outer shell 110 is made up of a plurality of ball panels 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, In the embodiment shown in Figures 2a-2c and 2e, ball panels 117, 11 8, 119 are made from particles that are bonded to each other at the surface. This is achieved by exposing the particles to heat. This is done by:

[0159] For example, the panels can be bonded together using RF and / or IR welding to bond the particles. For example, RF fusion can be used to bond particles 117, 118, 119. The surfaces of the substrate can be fused together to create panels 117, 118, 119.

[0160] However, in other embodiments, the ball panels 117, 118, 119 may include additional foam. The surface of the particles may be coated in different ways, for example, using a binder. Furthermore, the panels 117, 118, and 119 may be joined together by or the same foam material with different physical properties, e.g., density. It is possible.

[0161] Ball panels 117, 118, and 119 are of the same shape as that adopted in the finished ball 100. a three-dimensional curve shape that essentially corresponds (i.e., up to manufacturing-related tolerances) to the shape (however, this During the manufacture of ball 100, the ball may be produced so that it already includes a three-dimensional Preformed ball panels 117, 118, 119 were placed on a ball carcass 130 However, the panels 117, 118, and 119 can be connected to each other later. , for example by rotational molding, and then joined together, and then a ball carcass 130 or bladder is inserted. It is also possible to do this.

[0162] The exploded view of Figure 2d shows the three-dimensional design of the ball panels 117, 118, 119 in detail. In the embodiment shown, each of the ball panels 117, 118, 119 includes four wings. These interlock with the wings of each adjacent ball panel to form the first layer 110. Six ball panels are used in this design. However, other designs of ball panels (not shown) are also possible, even if the ball panel has a different shape than shown here. Although the shape of the panels can vary between panels on a given ball, different numbers of panels can be used. It may also be "possible."

[0163] In the embodiment shown in Figures 2a to 2e, the panels 117, 118, 119 of the first layer 110 The outward facing surface 101 of the ball 100 provided by surface 111 may include a textured surface. and / or plastic coating and / or plastic foil material on the outside We again mention the possibility that the texture surface and / or or plastic coatings and plastic foils. The possibilities are also fully applicable to the embodiments shown in Figures 2a to 2e.

[0164] The result of the application of the foil material can be seen in the exploded view shown in Figure 2d, where ball panel 117, 1 The surfaces of 18, 119 are covered with a "skin layer" comprising a plastic foil material 170, which The ball 100 is designed to have a sleek, sleek design that can be used to modify the ball's appearance while also improving the feel, handling, and aerodynamic characteristics. Affects gender.

[0165] 3a-3c show cross sections through the center of a further embodiment of ball 100 of the present invention. Again, for the sake of brevity, only a few of the embodiments of ball 100 shown in FIGS. 3a-3c are shown. Only certain features of are noted below.

[0166] In each embodiment of ball 100 shown in FIGS. 3a-3c, the ball includes a first layer 110. 1a-1c, the first layer 110 includes particles of a foam material. The description at the beginning of the detailed explanation of i applies. In the embodiment of 100, the first layer 110 is shown to include a closed surface, although this is not required. Alternatively, the first layer 110 may include one or more holes, or the first layer 1 10 may further include a plurality of distinct surface regions.

[0167] Again, the inner surface of the first layer 110 defines a conceptual delimiting surface 112, and the cavity 120 is , are located within a spatial region delimited or bounded by delimiting surface 112. Additionally, the delimiting surface 112 allows the embodiment of ball 100 shown in Figures 3a-3c to be However, the statement that the product does not include an inflatable bladder or Such a ball carcass may optionally be added with or without an inflatable bladder.

[0168] In each of the embodiments shown in Figures 3a-3c, ball 100 includes particles of a foam material. The elastic properties of the particles are at least partially transferred to the support structure 150. Therefore, the support structure 150 is not completely rigid. 50. The support structure 150 may optionally be made of other foam or non-foam materials. In the embodiment shown in Figures 3a-3c, the support structure 150 may include At least one wall, bar 157, or inner shell 155 extending within the cavity 120 Includes.

[0169] For example, in the embodiment of ball 100 shown in FIG. 3a, support structure 150 comprises a plurality of concentric spheres. The inner shell 155 is formed by one or more walls and / or bars 157. Thus, they are connected to each other and to the first layer 110 .

[0170] In the embodiment of ball 100 shown in FIG. 3b, support structure 150 includes a plurality of walls or bars 15 Contains only 7.

[0171] The embodiment of ball 100 shown in FIG. 3c has multiple elements interconnected in a honeycomb structure. A support structure 150 in the form of an element 159 is provided. The element 159 may be, for example, a wall or a bar. In this case, the entire support structure 150 is provided by such elements 159, In other embodiments, only certain areas of the support structure 150 have such a honeycomb structure. For example, in the case of ball 100 shown in FIG. 3a, a honeycomb structure may be included. Such element 159 is located between outermost inner shell 155 and first layer 110 of ball 100. It may be placed between

[0172] The embodiment shown in FIG. 3c is one in which the support structure 150 has at least one region with a repeating configuration. 1 shows a specific example of ball 100, including a support structure 150, which is a repeating unit or can contain unit cells (one honeycomb in the case of Figure 3c), and these unit cells are positioned adjacent to one another to form at least one region of the support structure 150. Several unit cells may each have the same three-dimensional shape, but each The size may vary.

[0173] However, the support structure 150 includes at least one region having a periodic configuration. In this case, the unit cells arranged adjacent to each other may be arranged as shown in FIG. , not only have the same three-dimensional shape but also have the same size.

[0174] The unit cell may be a honeycomb, as shown in Figure 3c. The unit cell may be a sphere. The unit cell may be a cube. The unit cell may be a rectangular prism. The unit cell may be a triangular prism. The unit cell may be an octagonal prism. The unit cell is a tetrahedron. The unit cell may be a square pyramid. The unit cell may be a cylinder. The unit cell is Those skilled in the art will recognize several other alternatives to achieve the same desired effect. It will be appreciated that alternate unit cells are possible.

[0175] In the embodiment shown in FIG. 3a, the inner shell 155 is a concentric spherical shell, as previously described. However, the illustrations of FIGS. 3a to 3c show the center of the ball 100. 1. The three-dimensional structure of the support structure 150 is not shown in the figure. Note that in the embodiment shown in Figure 3b, the support structure The individual elements of 150 can be provided, for example, as walls or bars 157. In the embodiment shown in FIG. 3c, the support structure 150 is, for example, The honeycomb structure shown can be provided by parallel tubes, which are However, the support structure 150 is formed by the wall of each of the balls 100. Or it could include a three-dimensional design showing the honeycomb structure along several different cross sections. Further possible embodiments will be apparent to those skilled in the art.

[0176] A balanced ball 100 can be provided that is free of any undesirable imbalance. As such, it may be advantageous for the support structure 150 to have some degree of symmetry. However, as mentioned above, in certain applications such as bowling or bowls, It may be desirable to impart such an imbalance to ball 100.

[0177] The support structure 150 has at least one rotational symmetry with respect to a rotation of a particular symmetry angle. It may be particularly advantageous to rotate the ball 100 about an axis of symmetry that runs through the center of the ball 100. The symmetry may be, for example, two-sided, three-sided, four-sided, five-sided, six-sided, or contiguous. The symmetry may be rotational, i.e. the angles of symmetry may be 180°, 120°, 90°, It can be 72°, 60°, or any angle.

[0178] For example, the support structure 150 of the embodiment shown in FIG. 3a first passes through the center of the ball 100. It is symmetrical with respect to a 180° rotation around an axis of symmetry perpendicular to the image plane. 155 are connected by a common bar 157 at the image plane, the support structure 150 Any axis of symmetry around the axis of symmetry passing through the center of the ball 100, lying in the plane and extending in the direction of the bar 157. It is rotationally symmetric.

[0179] In contrast, in the embodiment shown in FIG. 3b, the walls or bars 157 of the ball 100 the same angle between each other with respect to an axis of symmetry that is perpendicular to the plane and extends through the center of the ball 100 In the illustrated case, the angle α=72°, and the support structure 150 is aligned with this axis of symmetry. It has five-sided symmetry.

[0180] By proper design of the honeycomb structure and proper placement within the cavity 120, the honeycomb structure shown in FIG. The support structure 150 of the illustrated embodiment of ball 100 is positioned at the center of ball 100, perpendicular to the image plane. It may also have rotational symmetry, for example six-sided rotational symmetry, around an axis of symmetry passing through

[0181] The support structure 150, optionally together with the first layer 110, may contain one or more gases, e.g. For example, one or more chambers 160 may be defined that can be filled with air or nitrogen. If the walls of the chamber 160 are provided to be essentially impermeable to one or more gases, the gases may also be maintained above atmospheric pressure within chamber 160.

[0182] This allows the cavity 120 to be subdivided into individual regions or cells by the chambers 160. This allows the elastic properties of the ball 100 to be determined particularly precisely and easily. This allows for more precise control than is possible with a hydraulic bladder. All of this is further detailed above in the context of the description of Figures 1c and 1i.

[0183] To achieve essentially gas-impermeable walls of the chamber 160 in such a manner, At least a portion of the support structure 150 itself and / or a portion of the support structure 150 and the first layer 1 10 as a single unit. , the surfaces of the particles of the support structure 150 and the surfaces of the particles of the first layer 110 may be, for example, They may be bonded directly to one another, where the support structure 150 contacts the first layer 110. In an embodiment, multiple separate components of ball 100 are first manufactured and then assembled into a finished ball. The ball is then finished into a support structure 150 or a finished ball 100. In each case, the ball carrier It should be noted that ball 100 may be provided without a core, and in particular without an inflatable bladder. Therefore, it is possible to provide an advantage that the first layer 110 and the support structure 150 are made of particles of foam material. It is advantageous that the foam material itself can provide excellent elastic properties. This can be important in a beneficial way.

[0184] However, the support structure 150 may be used without the first layer 110 containing particles of foam material. The support structure 150 may be combined with, for example, a conventional ball panel. They may also be used in combination.

[0185] In this regard, the specific embodiments so far have all relevant features having at least a substantially spherical shape. Note that the ball 100 shown is a ball having a sphere shape. However, the present invention is not limited to balls having other geometries. balls, including rugby balls and American football balls Good too.

[0186] 4a-4b and 5a-5b show a method for manufacturing the ball 100 of the present invention. An embodiment of the method 200 is shown. However, in FIGS. 4a-4b and 5a-5b are schematic diagrams only and do not necessarily represent the actual dimensions encountered when actually performing method 200. do not have.

[0187] In the embodiment shown in FIGS. 4a-4b, the method 200 includes displacing particles 210 of the foam material into a rotating mold. 220. Thereafter, at least a portion of the ball 100 is rotationally molded. 30. Using the resulting centrifugal force and under the influence of thermal energy, the particles 210 The cavity 120 is pressed against a rotating mold 220, simultaneously fusing its surface. A one-piece ball 100 can be made having first layer 110. Method 200 includes: This may involve the continuous production of multiple layers by rotational molding 230 .

[0188] In another embodiment, the method 200 includes particles 210 of foam material, which are subsequently assembled. panels 117, 118, and 119 that at least partially form ball 100. This includes the manufacture of multiple ball panels such as:

[0189] As previously mentioned, in one embodiment, the manufacture of the individual ball panels 117, 118, 119 However, high frequency (HF) welding, e.g. radio frequency (RF) welding and / or infrared (IR) welding For example, individual ball panels 117, 118, 119 may be bonded together using adhesive. Fabrication of 19 may include fusing the surfaces of the particles using RF welding.

[0190] All of the ball panels 117, 118, 119 of a given ball 100 are arranged in this manner. Alternatively, only some of the panels may be manufactured in this manner, with the other panels of the ball remaining unmanufactured. are prepared using different methods, for example as described below.

[0191] Additionally, the use of HF welding, RF welding, RF fusion welding and / or IR welding may As previously mentioned, the present invention is not limited to the manufacture of balls 100, including balls 117, 118, and 119. may also be used to manufacture other embodiments of ball 100 of the present invention.

[0192] 5a-5b, another embodiment of the manufacture of the individual ball panels 117 is shown. The embodiment includes the step of loading particles 210 of foam material into a mold 250 (loading is not explicitly shown). and compression molding the particles 210 in a mold 250. Before loading the foil into the mold, the method 200, in the illustrated embodiment, 5a-5b, a first foil material is formed in a mold 250. The plastic foil material 170 may be a plastic foil material 170. The plastic foil material 170 in the mold 250 In this case, the forming of the plastic foil material 170 using the vacuum line 255 of the mold 250 This is done by deep drawing 260.

[0193] A plastic foil material 170 is applied over the outer surface 111 of the panel 117 and therefore over the bottom surface 111 of the panel 117. In the assembled state of ball 100 (see, for example, FIG. 2d), The outer surface 101 of the ball 100 is located on the outer surface 101 of the ball 100, and therefore the appearance and The mold 250 may be designed to affect the size and performance of the mold. The foil material 170 may, for example, increase the wear resistance of the panel 117 and therefore the ball 100. It may serve a decorative or decorative purpose.

[0194] The compression molding may be performed by a laser variotherm method. The heating and cooling channels are located very close to the surface. The surface of the mold 250 can be rapidly heated and cooled. The range is 100 Kelvin for 20 seconds. For some molding configurations, the heating channel configuration may be adjusted to a specific It is also possible to combine it with heating equipment and liquids.

[0195] The surface of the mold 250 is at a temperature of 80°C to 200°C, for example, 100°C to 180°C, The temperature may be 135°C to 145°C. This is because the individual ball panels 117 are released from the mold. As a result, the process cycle time for manufacturing the panel 117 can be significantly reduced. For example, the time before demolding may be less than 5 minutes, or even less than 3 minutes. It may be full.

[0196] Instead of forming the first foil material in the mold 250 before loading the particles 210 into the mold 250, Alternatively, the first foil material may be applied after the particles 210 are compression molded.

[0197] Additionally, the method 200 may, in a further possible embodiment of the method, include applying a second foil material to the panel. 117, 118, 119, in particular by applying the second foil material to some or all of the panels 11 7, 118, 119. Alternatively, Additionally, the method 200 may include, for example, assembling the ball panels 117, 118, 119. Later, the outward facing surface 101 of the ball 100, particularly portions of the ball panels 117, 118, and 119 Alternatively, it may include applying a spray material to the entire exterior surface 111. This may result in a multi-layer filter. The different layers of the film have different properties. The multilayer film may include an abrasion resistant layer. The multilayer film may include an ultraviolet resistant layer. The multilayer film may include a layer to modify the optical properties of the surface.

[0198] Instead of applying a foil layer during the processing of the panels 117, 118, 119 during molding, the foam particles 2 It is also possible to apply the coating as a spray coating after the panel 117, 118, 119 is formed. can be done.

[0199] When forming thicker layers, refer to DE102012206094A1 or EP2649 Using steam molding as described in 896A2, particles are formed by applying thermal energy. 210 may be fused.

[0200] When making a solid ball 100 of foam material, the ball 100 is made in segments. The segments may be further fused together by fusion bonding or infrared welding or gluing. It is possible.

[0201] Again, the foam material of the particles 210 used in the method 200 may be the following material: foam Thermoplastic polyurethane (eTPU), expanded polyether block amide (ePEBA), Expanded polyamide (ePA), expanded polypropylene (ePP), expanded polystyrene (ePS ), and expanded ethylene vinyl acetate (eEVA).

[0202] In some methods of manufacture, layers 110, 180, 181, 182 and / or or panels 117, 118, 119 to the carcass 130 of the ball 100 by melt bonding. They may also be combined.

[0203] Further examples are provided below to facilitate understanding of the invention.

[0204] 1. A ball (100), in particular a soccer ball, comprising particles (210) of a foam material.

[0205] 2. The foam material may be any of the following materials: foamed thermoplastic polyurethane, eTPU, foamed Polyether block amide, ePEBA, expanded polyamide, ePA, expanded polypropylene A small amount of polyethylene, ePP, expanded polystyrene, ePS, expanded ethylene vinyl acetate, eEVA At least one ball (100) according to Example 1.

[0206] 3. The method according to example 1 or 2, in which the particles (210) are bonded to one another at the surface, in particular fused. Ball (100).

[0207] 4. The plastic coating and / or plastic foil material (170) The ball according to any one of Examples 1 to 3 is disposed on the outward surface (101) of the ball (100). Lu (100).

[0208] 5. The outer surface (101) of the ball (100) and / or the plastic coating of Example 4 and / or the plastic foil material (170) of Example 4 has a textured surface. The ball (100) according to any one of Examples 1 to 4, comprising a shaped surface. .

[0209] 6. At least a first layer of particles (210) of foam material, in particular provided as an outer shell. The ball (100) of any one of Examples 1 to 5, comprising a layer (110).

[0210] 7. A plurality of layers (110, 180, 181, 182, 183, 184, 185, 186, 187, 188, 189, 190, 191, 192, 193, 194, 195, 196, 197, 198, 199, 200, 201, 202, 2). The ball (100) of Example 6.

[0211] 8. The thickness of layers (110, 180, 181, 182) and / or the thickness of layers (110, 180 , 181, 182), in particular the composition of the foam material of the particles (210), and / or At least one process parameter for the manufacture of the layers (110, 180, 181, 182) The meter changes between at least one of the layers (110, 180, 181, 182). The ball (100) described in Example 7.

[0212] 9. The first layer (110) has a thickness in the range of 0.5 mm to 10 mm, preferably 1 mm to 5 mm. The ball (100) according to any one of Examples 6 to 8, having a thickness in the range of

[0213] 10. A plurality of ball panels, the first layer (110) of which has particles (210) of foam material. The ball (100) according to any one of Examples 6 to 9, including (117, 118, 119). .

[0214] 11. Assemble the 3D preformed ball panels (117, 118, 119) The ball (100) according to Example 10 can be at least partially produced by the above method.

[0215] 12. A method for manufacturing a ceramic substrate, comprising: forming a ceramic substrate having at least one cavity (120); The ball (100) according to any one of Examples 6 to 11, which is disposed around a body (120). .

[0216] 13. The first layer (110) forms a ball carcass (130) surrounding a cavity (120). The ball (100) of Example 12 is placed on top.

[0217] 14. The ball according to Example 13, wherein the ball carcass (130) comprises an inflatable bladder (131). Rule (100).

[0218] 15. The cavity (120) is filled with at least one gas at a pressure higher than atmospheric pressure. The ball (100) according to any one of Examples 12 to 14.

[0219] 16. Support structure (150), in particular elastic support structure (1), having particles (210) of foam material 50). The ball (100) according to any one of Examples 1 to 15.

[0220] 17. The support structure (150) may include walls extending within the cavity, bars ( 157), and an inner shell (155) extending within the cavity; The ball (100) of Example 16 combined with any one of Examples 12-15.

[0221] 18. Example 1, wherein the support structure (150) includes at least one spherical inner shell (155). 6 or 17. A ball (100) according to claim 6 or 17.

[0222] 19. The support structure (150) comprises at least one region having a repeating conformation, e.g. 19. The ball (100) according to any one of 16 to 18.

[0223] 20. The support structure (150) is oriented around an axis of symmetry that runs through the center of the ball (100). Examples 16 to 19 have at least one rotational symmetry with respect to the rotation of the symmetry angle (α). The ball (100) according to any one of the preceding items.

[0224] 21. The symmetry angle (α) is 120°, 90°, 72°, 60°, or a continuous rotation. The ball (100) described in Example 20 is one of the above.

[0225] 22. The first layer (110) and / or the support structure (150) comprises at least one Chambers (160) are defined, and preferably at least one chamber (160) is filled with atmospheric air. 22. The bottle according to any one of Examples 6 to 21, wherein the bottle is filled with at least one gas having a pressure higher than that of the bottle. Rule (100).

[0226] 23. At least a portion of the first layer (110) and at least a portion of the support structure (150) The ball (100) of Example 22 is manufactured integrally as a single piece.

[0227] 24. The ball (100) of any one of Examples 1 to 11, which is a solid ball.

[0228] 25. The ball (100) of Example 24, comprising a core (190) of a non-foam material.

[0229] 26. Any one of Examples 1-13 or 15-25 not including an inflatable bladder (131). The ball (100) described in

[0230] 27. Method (200) for producing the ball (100) according to any one of Examples 1 to 26 .

[0231] 28. Loading particles (210) of foam material into a rotating mold (220) and balls (1 and rotationally molding (230) at least a portion of the ball (100). How to make it (200).

[0232] 29. Continuous formation of multiple layers (110, 180, 181, 182) by rotational molding (230) The method of Example 28, including manufacturing (200).

[0233] 30. A ball containing particles (210) of foam material and assembled at least partially into a ball. manufacturing a plurality of ball panels (117, 118, 119) forming a ball (100), A method (200) for manufacturing a ball (100).

[0234] 31. The manufacture of individual ball panels (117, 118, 119) is carried out by using particles of foam material (2 10) into a mold (250), and compressing the particles (210) in the mold (250). and compressing the mixture (200) to form a composite.

[0235] 32. The method according to Example 31, wherein the compression molding includes compression molding performed by a laser variotherm method. The method described in (200).

[0236] 33. Before loading the particles (210) into the mold (250), a first foil material is placed in the mold (250). ), in particular vacuum forming (260) the first foil material into the mold (250). The method (200) of Example 31 or 32, further comprising:

[0237] 34. Compression molding is performed at a temperature of 80°C to 200°C, preferably 100°C to 180°C; Particularly preferably, the reaction is carried out at a temperature of 135°C to 145°C, as described in any one of Examples 31 to 33. The method described in (200).

[0238] 35. Before the individual ball panels (117, 118, 119) are demolded, The process cycle time for the manufacture of 118, 119) is less than 5 minutes, preferably less than 3 minutes. The method (200) according to any one of Examples 31 to 34, wherein

[0239] 36. Applying a second foil material to some or all of the panels (117, 118, 119). , in particular, by vacuum forming a second foil material onto some or all of the panels (117, 118, 119). The method (200) of any one of Examples 30 to 35, further comprising:

[0240] 37. The foam material is one of the following materials: foamed thermoplastic polyurethane (eTPU), foamed Polyether block amide ePEBA, expanded polyamide ePA, expanded polypropylene e At least one of PP, expanded polystyrene (ePS), and expanded ethylene vinyl acetate (eEVA) The method of any one of Examples 28 to 36, comprising:

[0241] 38. The spray material is applied to the outer surface (101) of the ball (100), especially the ball panel (11 7, 118, 119) to a part or all of the outer surface of Examples 28 to 37. The method according to any one of the preceding claims.

[0242] Different arrangements of the components shown and described above, as well as components and sequences not shown or described, may be used. Similarly, some features and subcombinations are useful and others are not. The features and subcombinations may be used without regard to the limitations of the embodiments of the present invention. It is set forth for purposes of illustration and not for purposes of definition, and alternative embodiments may become apparent to the reader of this patent. Therefore, the present invention is not limited to the embodiments described and illustrated above, but Various embodiments and modifications are possible without departing from the scope of the claims. [Explanation of symbols]

[0243] 100 balls 101 Outward facing 110 First Layer 111 Exterior 112 Separator 115 holes 117, 118, 119 Ball Panel 120 cavity 130 Ball Carcass 131 Inflatable Bladder 135 Valve Unit 150 Support structure 155 inner shell 157 Bar 159 elements 160 Chamber 170 Plastic foil materials 180, 181, 182 layers 190 cores 200 ways 210 particles 220 Rotational mold 230 Rotational Molding 250 molds 260 Deep drawing α symmetry angle

Claims

1. at least one outer shell made of particles of a foam material; at least one cavity; The ball wherein the outer shell is disposed around the cavity, the outer shell comprising a plurality of spherical or angular chambers.

2. 2. The ball of claim 1, wherein the foam material comprises at least one of the following materials: expanded thermoplastic polyurethane, eTPU, expanded polyether block amide, ePEBA, expanded polyamide ePA, expanded polypropylene, ePP, expanded polystyrene, ePS, expanded ethylene vinyl acetate, eEVA.

3. 3. The ball of claim 1, wherein the particles are bonded to one another.

4. The ball of any one of claims 1 to 3, wherein a plastic coating and / or a plastic foil material is disposed on the outward facing surface of the ball.

5. The ball according to claims 1 to 4, wherein the outward facing surface of the ball and / or the plastic coating and / or the plastic foil material comprises a textured surface.

6. The ball of any one of claims 1 to 5, comprising at least a first layer of the particles of the expanded material, the first layer being provided as the outer shell.

7. The ball of claim 6 comprising multiple layers.

8. 8. The ball of claim 7, wherein the thickness of the layer and / or the material composition of the layer and / or at least one process parameter for manufacturing the layer varies among at least one of the plurality of layers.

9. The ball of any one of claims 6 to 8, wherein the first layer has a thickness in the range of 0.5 mm to 10 mm.

10. The ball of any one of claims 6 to 9, wherein the first layer includes a plurality of ball panels having the particles of the foam material.

11. 11. The ball of claim 10, which is manufacturable at least in part by assembling three-dimensional preformed ball panels.

12. The ball of any one of claims 6 to 11, including at least one cavity, the first layer being disposed about the cavity.

13. The ball of claim 12 , wherein the first layer is disposed on a ball carcass surrounding the cavity.

14. The ball of claim 13 , wherein the ball carcass includes an inflatable bladder.

15. The ball of any one of claims 12 to 14, wherein the cavity is filled with at least one gas at a pressure greater than atmospheric pressure.

16. The ball of any one of claims 1 to 15, including a support structure having the particles of the expanded material.

17. 17. The ball of claim 16 in combination with any one of claims 12 to 15, wherein the support structure includes at least one of a wall extending within the cavity, a bar extending within the cavity, and an inner shell extending within the cavity.

18. 18. The ball of claim 16 or 17, wherein the support structure includes at least one spherical inner shell.

19. The ball of any one of claims 16 to 18, wherein the support structure includes at least one region having a repeating configuration.

20. 20. The ball of any one of claims 16-19, wherein the support structure has at least one rotational symmetry with respect to a rotation of an angle of symmetry (α) about an axis of symmetry extending through the center of the ball.

21. 21. The ball of claim 20, wherein the angle of symmetry (α) is one of 120°, 90°, 72°, 60°, or a continuous rotation.

22. 22. The ball of any one of claims 6 to 21, wherein the first layer and / or the support structure define at least one chamber, the at least one chamber being filled with at least one gas at above atmospheric pressure.

23. 23. The ball of claim 22, wherein at least a portion of the first layer and at least a portion of the support structure are integrally manufactured as a unitary piece.

24. 10. The ball of claim 1, comprising a core of a non-foam material.

25. The ball of any one of claims 1 to 13 or 15 to 24, which does not include an inflatable bladder.

26. A method for making the ball of any one of claims 1 to 24, comprising loading particles of foam material into a rotational mold and rotationally molding at least a portion of the ball.

27. 27. The method of claim 26, comprising continuous production of multiple layers by rotational molding.

28. A method of manufacturing the ball of any one of claims 1 to 25, comprising manufacturing a plurality of ball panels comprising particles of expanded material and assembled to at least partially form the ball.

29. 30. The method of claim 28, wherein said manufacturing of individual ball panels comprises the steps of loading particles of said foam material into a mold and compression molding said particles within said mold.

30. 30. The method of claim 29, wherein the compression molding comprises compression molding performed by laser variotherm.

31. 31. The method of claim 29 or 30, further comprising forming a first foil material into the mold.

32. Any one of claims 29 to 31, wherein the compression molding is carried out at a temperature of from 80°C to 200°C. The method described below.

33. 33. The method of any one of claims 29 to 32, wherein the process cycle time for producing individual ball panels before demolding is less than 5 minutes.

34. A method according to any one of claims 28 to 33, further comprising applying a second foil material to some or all of the panel.

35. 35. The method of any one of claims 26 to 34, wherein the foam material comprises at least one of the following materials: expanded thermoplastic polyurethane, eTPU, expanded polyether block amide, ePEBA, expanded polyamide, ePA, expanded polypropylene, ePP, expanded polystyrene, ePS, expanded ethylene vinyl acetate, eEVA.

36. A method according to any one of claims 26 to 35, further comprising applying a blasting material to the outward facing surface of the ball.

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