Foamed Sponge Rubber Game Ball with Integrated Seams
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Solution Overview
Problem
Existing multi-layer sports balls do not effectively utilize a foamed intermediate layer to enhance performance characteristics such as compression, resilience, and coefficient of restitution, as the current methods for forming foamed layers are limited in creating a uniform and durable structure.
Innovation Solution
A method involving a foamed sponge rubber layer and raised seams formed from the outer layer sheets, where foamed sponge layer sheets with leaves are folded to cover an inflatable bladder and heat-molded to create a semi-finished carcass, which is then vulcanized to form a durable and resilient inflatable ball carcass with integrated seams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If foamable rubber panels are placed on the bladder and cured to form a foamed intermediate layer, then compression and resilience are improved, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-forming the foamed intermediate layer as a complete hemisphere shell before assembling the ball. The foamed layer is created in advance using foamable rubber panels that are cured together with the bladder and outer cover in a single preliminary molding operation, eliminating the need for subsequent layer-by-layer assembly and reducing manufacturing complexity.
Solution Approach 2:
The patent merges multiple manufacturing steps into a single integrated molding process. The bladder, foamed intermediate layer, and outer cover are formed simultaneously in one curing operation, combining what would traditionally be separate assembly steps into a unified manufacturing process that reduces time and complexity.
2Reliability
If foamable rubber panels are used to create the intermediate layer, then compression and resilience are enhanced, but manufacturing precision is reduced due to foaming variability
Solution Approach 1:
The patent applies parameter changes by carefully controlling the curing process parameters including temperature, pressure, and time. The mold is heated to a specific temperature range (150-200°C) and maintained under controlled pressure to ensure uniform foaming. This precise control of physical parameters ensures consistent cell structure and uniform thickness throughout the foamed intermediate layer.
Solution Approach 2:
The patent applies local quality by ensuring the foamed intermediate layer has uniform properties throughout its structure. The molding process is designed to create consistent cell size, wall thickness, and density across the entire hemisphere, with no weak spots or variations. This uniform local quality is achieved through proper mold design and controlled curing conditions.
3Strength
If multiple layers are assembled with separate seams, then durability is improved, but the manufacturing time and complexity increase
Solution Approach 1:
The patent merges the formation of multiple layers and seams into a single integrated molding process. The bladder, foamed intermediate layer, and outer cover are formed simultaneously with their seams created in one curing operation, eliminating the need for separate assembly steps and significantly improving manufacturing efficiency while maintaining structural integrity.
Solution Approach 2:
The patent applies preliminary action by pre-forming the complete multi-layer structure with all seams integrated during the initial molding process. The seams are created in advance as part of the single-cure operation, eliminating subsequent assembly operations and reducing manufacturing time while ensuring durable bonded joints.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in a multi-layer sports ball with improved foamed intermediate layers that enhance performance characteristics like compression and resilience, while also providing a durable and aesthetically appealing design with integrated raised seams.
Implementation Method 1
heat molding the semi-finished ball carcass to form an inflatable ball carcass having a sponge layer
Implementation Method 2
vulcanized to form a durable and resilient inflatable ball carcass with integrated seams
Data Source
AI summary
A method of making a game ball having a carcass comprising a foamed intermediate layer and a plurality of raised seams made from an outer layer is disclosed. The foamed intermediate layer may be formed from two sheets of foamed material. The sheets are shaped to have leaves that can be folded into the shape of a hemisphere with no gaps between adjacent leaves. The sheets are placed around a bladder, an outer layer is placed around the sheets, and the combination is heat molded. The seams are not made from strips of seam material placed on the outer layer of the carcass.