Closing final panels of machine sewn sports balls

Abstract

In a sports ball, such as a soccer ball, which comprises a plurality of shaped panels which are joined together by stitching to form an enclosed volume housing a bladder for inflation, several contiguous seams are left unstitched but are instead joined together adhesively by means of an underlying fabric patch. The contiguous seams are preferably provided with curved edges and markings to simulate stitching. The fabric patch is adhesively attached to the bladder (which preferably includes an over winding) and to the panels having the contiguous seams.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application contains subject matter which is related to the subject matter of the following applications, each of which is assigned to the same assignee as this application. Each of the below listed applications is hereby incorporated herein by reference in its entirety:

[0002] Sports Ball with Interior Reinforcement Safety Patches; Ser. No. 17 / 074,712 filed on Oct. 20, 2020.TECHNICAL FIELD

[0003] The present invention is generally directed to balls for sporting activities. More particularly, the present invention is directed to soccer balls, volleyballs and the like. Even more particularly, the present invention is directed to sports balls and their manufacturing processes. Even more particularly, the present invention is directed to improvements in the processes and structures that are employed at the point of closure to provide greater strength.BACKGROUND OF THE INVENTION

[0004] Applicant's prior application, cited above, teaches the use of patches lying along the seems of a sports ball to provide strength and cushioning. These patches are disposed over as many adjacent panel seems as desired. Complete coverage is not required and the parent application is silent about what happens at the point of closure. Closure occur at the end of manufacture when the panel structure is inverted, the bladder is inserted and the opening through which the bladder is inserted is closed. The present invention is directed to ball closure.

[0005] Whether or not sports balls such as soccer balls, and the like, are sewn by hand sewing or by machine sewing, the last couple of panels are always sewn by hand stitching. Unfortunately, this is a laborious process and requires skilled labor. This results in low production and higher costs.

[0006] There are other methods of ball production without sewing in which balls are produced by laminating the already cut panel over the rubber carcass by the use of adhesive or natural rubber bonding. Some other methods of production are called thermal bonding in which each panel's edges are curved all around and glued on the edges which lets the panel edges bond with each other by either cold bonding or by hot bonding methods.

[0007] In other methods of ball manufacture, in order to address the issue of high cost and low production which accompanies hand sewing of the last panels of machine sewn balls, last panels closing is performed by using the above mentioned thermal bonding method in which whole ball is sewn by machine except that the last few panels are shaped on their edges, turned to the sides, beveled and then affixed by the application of adhesive along the edges which are thus bonded with each other, either either by cold bonding or by thermal bonding.

[0008] The above described method of closing the last panels of machine sewn balls has its own problems because machine sewn ball exterior cover material typically consists of a thin film backed by soft foam which bond with each other on both confronting panels edges. With internal bladder pressure and exterior kicking during a game the film on both sides of adjacent panels elongates and can easily break because only glue is holding both panel edges together without any other support to strengthen the bonding on the inside.

[0009] The other flaw is that adhesive used in bonding the edges drips down and ends up on the interior inflating bladder which is already covered with textile thread. Eventually this means that the panels edges become bonded to the bladder surface. Thus, this undesirable bonding does not let the bladder flex or move easily inside the ball. In this situation, because the bladder is not floating freely inside the ball and only a portion of the bladder is attached to the backing of the exterior ball panel, the ball cannot bounce straight up in the air from the ground and turns in unpredictable directions when landing on the ground and bouncing up in the air. This is a major defect in this kind of ball.

[0010] In view of the above, there is a need to have a new and better method of bonding the last panels of machine sewn balls so as to reduce labor cost and enhance production; the details of the solution to these problems are found herein. From the above, it is therefore seen that there exists a need in the art to overcome the deficiencies and limitations described herein and above.SUMMARY OF THE INVENTION

[0011] It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter.

[0012] The shortcomings of the prior art are overcome and additional advantages are provided through a method of ball closure employing a patch beneath the seam at which closure is provided

[0013] In one aspect of the present invention, there is provided a sports ball comprising a plurality of panels stitched together to form an interior volume into which an inflatable bladder is disposed; certain select ones of the panels act to provide an opening for bladder insertion and closure of the ball; and, in accordance with a preferred embodiment of the present invention, a patch is disposed beneath the closure and is adhesively affixed to panel edges at said closure.

[0014] The patch of the present invention may be deployed either with or without the use of the patches as taught by the parent application which are deployed beneath as many of the seams as is desired.

[0015] Accordingly, it is an object of the present invention to improve the manufacture of a sports ball, such as a soccer ball.

[0016] It is another object of the present invention to make the manufacture of sports balls both cheaper and faster in that assembly is less laborious.

[0017] It is yet another object of the present invention to facilitate a structure in which the interior bladder is more able to float freely.

[0018] It is a still further object of the present invention to keep adhesive material used in ball manufacture away from the bladder and / or any windings disposed thereon.

[0019] It is still another object of the present invention to increase the strength of sports balls, especially those which are subject to extreme forces induced by kicking during play.

[0020] It is another object of the present invention to manufacture sports balls. Such as soccer balls, without the need for hand sewing.

[0021] Lastly, but not limited hereto, it is an even further object of the present invention to better bond together ball panels which lie at the point of closure.

[0022] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention.

[0023] The recitation herein of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:

[0025] FIG. 1 is an isometric view illustrating three adjacently positioned geometrically shaped panels such of those that are employed in the edges manufacture of soccer balls;

[0026] FIG. 2 is a view similar to FIG. 1 which more particularly illustrates the presence of curved edges;

[0027] FIG. 3 illustrates the placement of pentagonal and hexagonal panels, in which a closure opening consists of four panel edges;

[0028] FIG. 4 is a view similar to FIG. 3 in which only two panel edges remain to be permanently joined;

[0029] FIG. 5 illustrates the placement of adhesive material on the edges of three panels in a view in which the outer layer of the sports ball is shown inside out;

[0030] FIG. 6 is a view similar to FIG. 5 more particularly illustrating initial stages of the placement of a closure strip in accordance with the present invention;

[0031] FIG. 7 illustrates the use of fabric strips in accordance with the present invention in conjunction with panel seams that are sewn;

[0032] FIG. 8 illustrates the relationship between the structure shown in FIG. 7 and the interior bladder which is also found to be wound with thread material as shown;

[0033] FIG. 9 is an exploded view of facing panel edges with their ends abutting and more particularly intending to illustrate seams having conventional stitching;

[0034] FIG. 10 illustrates the traditional method of joining the final panel openings using an adhesive in which adhesive material ends up being dripped on thread material which has been wound on the bladder;

[0035] FIG. 11 is related to FIG. 3 and illustrates placement of a fabric strip covering four panel edges that surround the area left for bladder insertion;

[0036] FIG. 12 is similar to FIG. 11 but also showing the use of additional fabric cross strips for extra strength;

[0037] FIG. 13 is similar to FIG. 4 illustrating a fabric patch applied across two seams;

[0038] FIG. 14 is similar to FIG. 13 also showing the use of supplementary fabric cross strips;

[0039] FIG. 15 is an exterior view of a soccer ball in which only two seams are joined by the closure method shown herein; and

[0040] FIG. 16 is a view similar to FIG. 15 in which four seams are joined by the closure method shown herein.

[0041] FIG. 17 is a more detailed view of FIG. 10 which shows a completed seam in greater detail.DETAILED DESCRIPTION

[0042] In preferred embodiments of the present invention, all of the sports ball panels are sewn by machine and the sewing side of the ball is turned outside-in.

[0043] Firstly, all of the ball panels are sewn by a machine sewing method and the sewing side of the ball is turned outside in. In preferred embodiments of the present invention and, in particular for the manufacture of soccer balls, typically either two or four adjacent seams are left unsewn. It is through this area that a bladder is ultimately inserted. The present invention also provides these seams with shape edges so that the completed product is rendered more capable of being treated as if all of the panel edges appear to be sewn. These shape edges are described herein as being either curved, shaped, beveled or rounded. Once sewing of the whole ball is completed, these pre-shaped panels are left without sewing and their edges are applied with adhesive. After adhesive is dried then a fabric strip is placed underneath the unsewn panel edges which are already coated with bonding adhesive. A fabric strip is placed underneath the unsewn panel edges and serves to hold abutting edges together. Once the fabric strip is positioned to hold the panels edges from underneath, the edges are joined together and placed in a heating mold. With the application of heat in the mold, adhesive on the panel edges activates and bonds the intended panels together. Similarly, adhesive on the fabric strip underneath the panels bonds with the backing fabric of the ball's exterior panels thus providing a strong dual bonding of the panels. This bond is stronger than the traditional bonding method of only bonding the confronting edges together. The size and shape of the supporting fabric strip is designed to conform to the shape and size of exterior ball panel shapes.

[0044] In one aspect of the present invention (one with an opening provided by two adjacent seams), an opening is provided by two edges of one pentagonal panel which faces one each edge of two adjacent hexagonal panels. This varies from one ball to another depending on the shape of the ball. Different types and shapes of fabric strip are used to close and strengthen the final openings of a ball. The most important aspect of the fabric strip is that it spans and adhesively connects adjacent panels along the panels that form an opening for insertion of an inflatable bladder. The last closing panels edges are turned on their edges which are preferably beveled and glued to bond with each other.

[0045] In the manufacture of soccer balls, the panel edges are turned downward approximately 2 to 3 mm in the same way as they would be turned when sewing two panels together from its edge depending on the thickness of the material which can vary in practice. The panel edges then faces down substantially vertically and rest on the supporting fabric strip provided underneath for support and strength and for keeping glued edges together and preventing slippage and sliding when the ball is fully inflated and undergoes enormous kicking and shooting during play. Ball panel edges are turned in so as to resemble sewn edges which sit correctly and fit perfectly with other sewn panels.

[0046] Various aspects of the present invention are illustrated in the accompanying drawings. For example, FIG. 1 illustrates a set of typical panels 101-103 that typically comprise a sports ball. In particular, there is shown pentagonal panel 101 along with hexagonal panels 102 and 103. In a typical sports ball manufactured in accordance with the present invention hexagonal panels 102 and 103 are joined by stitching, preferably machine stitching. It is thus seen that pentagonal panel 101 shares to adjacent edges or seams with the other two panels. It is these other two seams that are relevant to the sports balls described herein.

[0047] FIG. 2 is similar to FIG. 1 except that it were clearly illustrates curved edges 110. These edges are joined adhesively in conjunction with the use of an underlying fabric strip that serves to more securely provide closure of the ball after insertion of the bladder through a temporary opening provided by curved or beveled edges 110.

[0048] As indicated above, the opening provided for sports ball closure may include any desirable number of contiguous or adjacent seams. However, in the case of a soccer ball, for example, it is convenient to use either a four-seam opening as shown in FIG. 3 or a two-seam opening as seen in FIG. 4. In the case of a four-seam opening as shown in FIG. 3 it is seen that hexagonal panel 102 having edges 102A and 102B are ultimately joined with edges 104A (on hexagonal patch 104) and 101A on pentagonal panel 101, respectively, as shown. Similar adjacency is provided between edge 103A on hexagonal patch 103 and edge 101B panel 101. A similar relationship exists for hexagonal panels 103 and 105 along edges 105A and 103B respectively.

[0049] FIGS. 5 and 6 illustrate an exemplary soccer ball made in accordance with the present invention. In particular, these two drawings indicate such a ball being inverted with the sewn seams present on the exterior of the two structures. In particular, these two drawings illustrate the presence of machine sewn seams 200. Additionally, final seams forming opening 140 are present using curved or beveled edges 110. For continuity purposes relative to FIG. 1-4, similarly positioned pentagonal panel 101 is shown in its relationship to hexagonal panels 102 and 103. More particularly, FIG. 6 indicates the presence of fabric strip 150 as it is being applied across opening 140. Importantly for one aspect of the present invention edges 110 are curved or beveled so that they may be made to work closely resemble a sewn seam, as described above.

[0050] FIG. 7 illustrates the relationship between two hexagonal panels 102 and 103 with respect to fabric strip 150. More particularly, it is seen that the hexagonal panels are joined by conventional stitching 200, perfectly provided by machine. It is further noted that curved or beveled edges 110 are shown as also being part of panels 102 and 103 all of which overlie fabric 150. FIG. 8 is similar to FIG. 7 except that it includes pentagonal panel 101 and also shows the relationship with bladder 160 which possesses windings 165 for strength and protection of inflatable bladder 160. FIG. 8 is also relevant in that curved or beveled edges of pentagonal panel 101 are shown in their final position. It is noted that for purposes of illustration FIG. 8 is an exploded view.

[0051] FIG. 9 illustrates the relationship between fabric strip 150 and edge seam 110 just prior to its being adjacently disposed. FIG. 10 illustrates the traditional method of joining the final panel openings using adhesive 111 in which adhesive material ends up being dripped on thread windings 165 provided over bladder 160. This is undesirable.

[0052] As mentioned elsewhere herein, one of the features that is provided in the present invention is the capability to render the final closure of the present invention more capable of resembling and / or simulating a sewn seam. As described above, beveled edges 110 are joined adhesively in an edge-to-edge fashion and in this way already resemble a sewn seam. However, it is noted that panels herein that are joined adhesively at the closure or also preferably provided with markings 112 which mimic stitching 200 present on other portions of the sports ball.

[0053] FIG. 17 illustrates a close up view of FIG. 10 so as to show a closer view of panel junctions 110 at the closing seam. Reference numeral 110 is best describable as the part of panel closure seams that are externally visible. The visible curved or beveled edges referenced herein by reference numeral 110 are seen in greater detail in FIG. 17 which shows these edges as including two specific regions which are not easily visible in a completed ball: a face region 113 (also describable as being a curved head) and substantially flat floor region 114 which is directly attached to fabric strip 150 using adhesive.

[0054] FIGS. 11 through 14 illustrates the placing of fabric strip 150 over the seams which participate in the final closure opening. It is through this opening that bladder 160 is inserted before final closure. In FIGS. 11 and 12 there is provided an example of fabric strip 150 being disposed over four seams, while FIGS. 13 and 14 illustrates fabric strip 150 being disposed across only two seams. Is noted that the present invention is capable of employing any convenient number of seams and is not limited to either two or four. Seams.

[0055] It is noted that fabric strips 150 may also be provided with cross steps 155A and 155B as shown in FIG. 12 when fabric strip 150 is disposed over a four seam opening. In situations where fabric strip 150 is disposed opposite only two seams as seen in FIG. 14, fewer cross strips 155 are provided.

[0056] FIGS. 15 and 16 provide exterior views of soccer balls manufactured in accordance with the present invention. In particular, in these drawings reference numeral 200 refers to conventional machine sewn seams. In contrast, closing seams in accordance with the present invention are illustrated by reference numeral 110. In FIG. 15 two such closing seams are shown. In FIG. 16 there are four such seams shown.

[0057] The panels of sports balls in accordance with the present invention (especially soccer balls) typically include three layers: a fabric layer, which is totally distinct from fabric strip 150, a middle foam layer and an outer layer which is typically a layer of TPU (thermoplastic urethane) or PU (polyurethane). In accordance with the present invention, it is seen that the faces of beveled edges 110 are turned and rest on fabric strip 150. When fully shaped, the top layer, middle foam and backing fabric become parallel to the rest of the flat body surface and stand horizontal to the rest of its area and lays flat on supporting fabric strip 150.

[0058] It is noted that the present invention finds particular utility in the manufacture of machine sewn sports balls; nonetheless, the methods and structures of the present invention are not limited to sports balls that are sewn only by machine. While the illustrations shown herein are directed to the manufacture of a soccer ball, the methods and structures of the present invention are applicable to the production of other sports balls. The present invention is especially directed to the construction of sports balls formed from a plurality of particularly shape panels that are sewn together by machine. Collectively, the stitched together panels form an enclosed volume into which to an inflatable bladder is inserted. In preferred embodiments of the present invention, the bladder is also wound with thread, cord, or string so as to provide improved play characteristics. It is also noted that the strip fabric comprises any kind of strong woven fabric having singular or multiple layers. Any type of strong adhesive is used to bond the panels and the fabric strip.

[0059] All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0060] Although the description above contains many specifics, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by the appended claims, in which reference to an element in the singular is not intended to mean “one and only one” unless explicitly so stated, but rather “one or more. ” All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 USC § 112, sixth paragraph, unless the element is expressly recited using the phrase “means for.”

[0061] While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the spirit and scope of the invention.

Claims

1. An object for sports play comprising:a plurality of exterior, stitched together panels sewn at their edges, configured to form a closed volume and forming, by said stitching, raised interior edges at the edges of said panels;an inflatable bladder occupying said closed volume;a subset of said plurality of exterior panels forming an adjacent set of said panels having edges lying at a closure for said ball; anda patch lying beneath and between said adjacent ones of said closure forming panels and adhesively affixed thereto.

2. The object of claim 1 in which said patch is further adhesively affixed to at least one of said panels3. The object of claim 1 in which said adjacent set of said panels have curved edges, whereby said edges more closely resemble said stitched together panels.

4. The object of claim 3 further including markings along said curved edges which simulate stitching;5. The object of claim 3 in which said curved edges are joined with adhesive.

6. The object for sports play of claim 1 which is in the shape of a soccer ball.

7. The object of claim 1 in which bladder is covered in an exterior winding for strength.

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