Ball Panel Outer Layer Molding with Integrated Textures
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Solution Overview
Problem
Existing methods for manufacturing ball panels are complex and require separate elements to influence optical, haptic, and aerodynamic properties, leading to reduced durability and resilience against external influences.
Innovation Solution
A method involving shaping a sheet of material in a mold to create three-dimensional panels with first and second textures on opposite sides, allowing for integrated control of aerodynamic, haptic, and optical properties, and enhancing durability through heat treatment and specific material choices like acrylonitrile-butadiene-styrene and thermoplastic urethane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate elements are used to influence optical, haptic, and aerodynamic properties, then these properties can be independently adjusted, but the manufacturing process becomes complex and durability decreases
Solution Approach 1:
The patent combines multiple functional elements (optical design foil, haptic texture, aerodynamic structure) into a single integrated outer layer component. This is achieved by molding the outer layer with embedded textures and integrated optical elements, eliminating the need for separate manufacturing steps and assembly operations, thereby reducing manufacturing complexity while maintaining the ability to independently adjust optical, haptic, and aerodynamic properties through material and structural design
2Ease of manufacture
If a smooth surface is used for the ball, then manufacturing is simpler, but aerodynamic properties deteriorate causing chattering and poor flight
Solution Approach 1:
The patent applies local quality by creating specific textured regions on the ball surface while maintaining smooth areas. The outer layer incorporates localized textures with specific patterns and dimensions that optimize aerodynamic performance in critical areas, while other regions remain smooth for manufacturing simplicity. This localized texturing approach ensures reliable aerodynamic properties without requiring the entire surface to be complex
3Ease of manufacture
If optical design is applied by imprinting or spraying on the panel surface, then the process is simple, but the optical design is rapidly impaired by abrasion and external influences
Solution Approach 1:
The patent implements the nested doll principle by embedding the optical design foil within the multi-layered outer layer structure. The optical design elements are nested between protective layers, with the design foil positioned between the front surface layer and the base outer layer. This nesting provides mechanical protection against abrasion and external influences while maintaining the simplicity of applying optical designs through foil embedding during the molding process
4Manufacturing precision
If multiple separate elements are used for optical and aerodynamic design, then each property can be optimized, but the constructive set-up becomes more complicated
Solution Approach 1:
The patent achieves universality by designing the outer layer to perform multiple functions simultaneously. The single outer layer component integrates aerodynamic texturing, optical design embedding, haptic surface properties, and structural protection all in one element. This multi-functional design allows optimization of optical and aerodynamic properties through integrated structural features rather than requiring separate components, thereby reducing constructive set-up complexity while maintaining manufacturing precision
Data Source
AI summary
Described are methods for manufacturing an outer layer for a panel of a ball, in particular of a football, an outer layer manufactured with such a method as well as a panel and a ball comprising such an outer layer. The method includes shaping a sheet of material in a mold, wherein the mold is formed in such a way that during shaping, the sheet of material assumes a three-dimensional shape of the outer layer of the panel. Moreover, the method includes creating first textures in at least a first partial region on a first side of the sheet of material and creating second textures in at least a second partial region of the sheet of material.