Seamless Inflatable Ball Manufacturing via Fluidic Layer Injection
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Solution Overview
Problem
Conventional inflatable balls have detachable surface layers and gaps that allow water to enter and air to escape, resulting in a rough outer surface that prevents smooth rolling.
Innovation Solution
A method of manufacturing a seamless inflatable ball by inflating a preformed body, applying a medium layer made of weaving material, forming a fluidic surface material, and placing it in molds with indentations to create a solid layer, then partially deflating and re-inflating to push the material into gaps, securing the layers and shaping the surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a surface layer is adhered or sewed on the spherical body, then the ball structure is formed, but the connection becomes complicated and the surface layer becomes easily detachable
Solution Approach 1:
The patent combines the spherical body and surface layer into a seamless integrated structure by injecting fluidic surface material that penetrates and bonds with the medium layer, eliminating the need for separate adhesion or sewing operations. This merging approach resolves the contradiction by creating a unified structure that is both simple to manufacture and reliably attached.
Solution Approach 2:
The patent uses composite material construction with a medium layer made of weaving material and fluidic surface material that forms a solid layer upon drying or solidification. This composite structure creates strong interlayer bonding that prevents detachment while simplifying the manufacturing process compared to traditional adhesion methods.
2Reliability
If a covering layer is connected in a heat melting manner, then the connection is improved, but air cannot be discharged and the surface layer is easily removed
Solution Approach 1:
The patent employs a medium layer made of weaving material with inherent porosity that allows air to pass through during the manufacturing process. The fluidic surface material is injected through these pores and bonds with the medium layer, creating a reliable connection while maintaining air discharge capability throughout the formation process.
Solution Approach 2:
The patent implements a dynamic manufacturing process where the spherical body is repeatedly inflated and deflated to facilitate air discharge and ensure proper bonding. The medium layer and covering layer are formed dynamically through this cyclic process, allowing air to be discharged at appropriate stages while maintaining connection reliability.
3Shape
If connection gaps are heated and pressed to form seamless ball, then the ball shape is improved, but the outer surface becomes rough and cannot roll smoothly
Solution Approach 1:
The patent applies local quality by using fluidic surface material that can be precisely controlled to fill connection gaps and form a uniformly smooth outer surface. The material is injected locally at gap locations and spreads to create an even coating, achieving both seamless shaping and high surface smoothness that enables smooth rolling.
Solution Approach 2:
The patent utilizes parameter changes by controlling the fluidic surface material's state from liquid to solid through drying or solidification. This phase change allows the material to flow into gaps and conform to the spherical shape, then solidify to create a smooth, seamless outer surface with high manufacturing precision.
4Reliability
If fluidic surface material is pushed into gaps of the medium layer, then the layers are securely connected, but the manufacturing process becomes more complex
Solution Approach 1:
The patent uses pneumatic injection to push fluidic surface material into the gaps of the medium layer. An injection nozzle delivers the material under pressure through the porous medium layer, securely connecting the layers. This pneumatic approach simplifies the process compared to manual methods while ensuring reliable layer connection.
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 securely connects the layers, prevents water entry, and creates a smooth outer surface for seamless inflatable balls of various shapes and sizes, ensuring they roll smoothly.
Implementation Method 1
partially discharging air out of the spherical body and inflating the air into the spherical body repeatedly so as to expand the spherical portion and to force the two inner walls of the ball molds, such that the fluidic surface material is pushed into the multiple gaps of the medium layer
Implementation Method 2
after the fluidic surface material is dried or is solidified to form a solid layer on the spherical portion
Implementation Method 3
after the fluidic surface material is dried or is solidified to form a solid layer on the spherical portion
Data Source
AI summary
A method of manufacturing a seamless inflatable ball contains: 1) inflating air into a preformed body so as to form a spherical body and covering a medium layer on the spherical body so as to form a semi-finished part; 2) forming a fluidic surface material on the medium layer of the semi-finished part in a predetermined thickness so as to produce a spherical portion with a covering layer; 3) placing the spherical portion into two ball molds; and 4) partially discharging air out of the spherical body and inflating the air into the spherical body repeatedly. In the step 3), the spherical portion is clamped in the two ball molds, and after the fluidic surface material is dried or is solidified to form a solid layer on the spherical portion, the spherical portion is removed from the two ball molds, thus forming a sphere.