Sport Ball Casing Bonding Process for Mass Reduction

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Solution Overview

Problem

Conventional inflatable sport balls have mass distribution and manufacturing efficiency issues due to stitched seams, which can be improved by adopting a bonding process for panel joining.

Innovation Solution

The sport ball features a layered configuration with a polymer foam middle layer and thermoplastic polymer materials, using a bonding process such as adhesive or thermal bonding to join panels, resulting in seams that protrude outward and reduce mass at seams, enhancing energy return and manufacturing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If panels are joined using stitching, then structural integrity is achieved, but mass at seams increases and manufacturing efficiency decreases

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidmass at seams

Core Design Contradiction:

ProductivityVSWeight of moving object

Solution Approach 1:

The patent replaces the mechanical stitching system with a thermal bonding system using thermoplastic polymer materials. The stitching needles and threads are substituted by heated bonding surfaces that melt and fuse the thermoplastic layers together, eliminating the need for mechanical penetration and thread insertion/removal processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the thermoplastic polymer material through temperature and pressure parameters. By heating the bonding surfaces above the melting point of the thermoplastic material and applying pressure, the material transitions from solid to molten state and back, creating a strong bond without mechanical stitching.

Inventive Principle:

Principle #35Parameter changes

2Strength

If stitching is used to join panels, then panels are securely connected, but the stitching process is time-consuming

Engineering Contradiction:

Improvepanel connection strengthVSAvoidstitching process time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent utilizes phase transitions of the thermoplastic polymer material to achieve bonding. The material transitions from solid to molten state during heating, allowing flow and fusion, then transitions back to solid state during cooling, creating a permanent bond between panels without mechanical stitching.

Inventive Principle:

Principle #36Phase transitions

3Weight of moving object

If conventional stitching methods are used, then seams are formed, but mass distribution is suboptimal

Engineering Contradiction:

Improvemass distributionVSAvoidseam structure complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent applies local quality by using thermoplastic polymer materials specifically at the seam regions where bonding is required, while the main panel bodies can use different materials optimized for their specific functions. This localized application of thermoplastic material at bonding zones enables precise control over mass distribution and structural properties at critical connection points.

Inventive Principle:

Principle #3Local quality

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 bonding process reduces the mass of seams, enhances the sport ball's performance properties, and increases manufacturing efficiency by eliminating the time-consuming stitching process, while providing a unique aesthetic and improved structural integrity.

Implementation Method 1

The panel is heated, thereby melting the thermoplastic polymer material

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

thereby melting the thermoplastic polymer material to effect bonding of the panels

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

using a bonding process such as adhesive or thermal bonding to join panels

Methodology Applied

Scientific EffectThermal bonding: Welding

Implementation Method 4

using a bonding process such as adhesive or thermal bonding to join panels

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP2726163B1Sport ball casing and methods of manufacturing the casing

Publication Date: 2017.07.26 NIKE INNOVATE CV

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AI summary

A sport ball (10) includes a casing (20) and a bladder (40). The casing includes a plurality of panels (21) having edge areas joined to each other with bonds, and the edge areas project toward an exterior of the ball. The bladder is located within the casing. In another aspect, the casing includes a first panel and a second panel that each have an exterior surface facing outward and an opposite interior surface facing inward. The interior surface of the first panel is bonded to the interior surface of the second panel to form a seam (22) that joins the first panel and the second panel together. A method of manufacturing the casing may include forming thermal bonds between the panels.