Soccer Ball Casing Using Two Hemispherical Panels
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Solution Overview
Problem
The complexity and cost of manufacturing traditional soccer balls are high due to the large number of panels required, which makes it difficult to reduce manufacturing steps while maintaining the traditional appearance.
Innovation Solution
A method of forming a spherical sport ball casing using two substantially hemispherical panel components joined at a non-linear, circumferential seam, with elongated indentations forming sides of the central panel and flange areas that abut to create a vertex, reducing the number of seams and manufacturing steps while maintaining the traditional look.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a traditional soccer ball uses thirty-two panels (twelve pentagonal and twenty hexagonal), then the traditional appearance is maintained, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent combines multiple traditional panels into two hemispherical shell components, each formed from a single sheet of material. This merging reduces the panel count from thirty-two individual panels to just two integrated hemispherical structures, significantly simplifying manufacturing while maintaining the traditional soccer ball appearance through strategic placement of seams and panel configurations.
Solution Approach 2:
The patent segments the traditional thirty-two panel configuration into two hemispherical shell components joined at an equatorial seam. Each hemisphere is further segmented into a central panel and peripheral panels that, when assembled, recreate the traditional pentagonal and hexagonal panel pattern, thus maintaining appearance while reducing manufacturing complexity.
2Device complexity
If the number of panels is reduced to simplify manufacturing, then manufacturing complexity decreases, but the traditional-looking soccer ball pattern is not maintained
Solution Approach 1:
The patent transitions from a two-dimensional panel arrangement to a three-dimensional hemispherical shell structure. By forming each hemisphere as a curved surface from a single sheet and then joining two hemispheres, the invention creates a spatial configuration that naturally produces the traditional panel pattern through the geometry of the spherical shape rather than through complex flat panel assembly.
Solution Approach 2:
The patent employs spherical geometry by forming two hemispherical shell components that are joined to create a complete sphere. The curvature of these hemispherical shells naturally distributes the panel patterns in a way that replicates the traditional soccer ball appearance, using the three-dimensional spherical form to achieve the desired aesthetic without requiring thirty-two separate flat panels.
3Device complexity
If two hemispherical panel components are joined at a non-linear circumferential seam, then the number of seams is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates preliminary action by pre-forming the two hemispherical shell components with predetermined shapes and features before assembly. The non-linear circumferential seam is pre-configured into each hemisphere during the forming process, allowing for more tolerant final assembly since the complex geometry has already been established in the individual components rather than requiring high-precision alignment during joining.
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
This approach simplifies the manufacturing process, reduces material usage at seams, and enhances the structural integrity and appearance of the ball, achieving a more efficient and cost-effective production method while maintaining the traditional design.
Implementation Method 1
joining together the first substantially hemispherical panel component and the second substantially hemispherical panel component at a non-linear, circumferential seam
Data Source
AI summary
A method of making a spherical sport ball includes forming a casing having a first and a second substantially hemispherical panel component. The first panel component is a first unitary structure and has a first central panel, a first plurality of polygonal peripheral panels adjacent to the first central panel and having a first plurality of edges, and a plurality of flange areas extending from the first plurality of edges. The second panel component is a second unitary structure and has a second central panel and a second plurality of polygonal peripheral panels adjacent to the second central panel. The method includes joining together the first panel component and the second panel component at a non-linear, circumferential seam between the first and second plurality of polygonal peripheral panels. The method also includes forming a vertex between adjacent ones of the plurality of flange areas.