Sport Ball Indented Casing with Intermediate Structure
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Solution Overview
Problem
Conventional inflatable sport balls face challenges in achieving a balanced structure that provides both durability and aerodynamics, while also ensuring a comfortable feel and controlled expansion, which existing designs struggle to optimize simultaneously.
Innovation Solution
The sport ball configuration features a layered structure comprising a casing, an intermediate structure, and a bladder, where the intermediate structure includes a compressible foam layer or energy-returning rubber layer to restrict bladder expansion, and the casing is formed from durable panels with strategically placed indentations for enhanced aesthetics and control, using a manufacturing process that bonds the layers through heat and pressure to create a seamless appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the casing is formed from multiple durable panels joined together, then the durability and wear resistance are improved, but the aerodynamics and panel configuration complexity increase
Solution Approach 1:
The casing is divided into multiple durable panels (traditionally 32 panels with pentagonal and hexagonal shapes) that are joined together along abutting edge areas. This segmentation allows each panel to be optimized for durability while the overall configuration can be adjusted to improve aerodynamics, resolving the contradiction between durability and aerodynamic efficiency.
2Ease of operation
If the intermediate structure is added to provide softened feel and energy return, then the comfort and energy efficiency are improved, but the structural complexity and manufacturing difficulty increase
Solution Approach 1:
An intermediate structure is introduced between the casing and the bladder to serve as a mediator. This intermediate layer provides the softened feel and energy return while the patent simplifies its integration by allowing it to be bonded or joined to either the casing or the bladder, reducing the overall structural complexity compared to having separate complex mechanisms for each function.
Solution Approach 2:
The intermediate structure is designed to perform multiple functions simultaneously: providing softened feel, imparting energy return, and restricting bladder expansion. By combining these functions into a single intermediate structure, the patent reduces the need for separate components, thereby simplifying the overall structure while maintaining comfort and energy efficiency.
3Volume of moving object
If the bladder is made inflatable to provide interior portion, then the volume and flexibility are improved, but the risk of over-expansion and structural integrity worsen
Solution Approach 1:
The intermediate structure acts as a mediator between the inflatable bladder and the outer casing. It restricts the expansion of the bladder, preventing over-inflation that could compromise structural integrity, while still allowing the bladder to provide the necessary interior volume and flexibility when properly inflated.
4Strength
If panels are joined with stitching or adhesives to form casing, then the durability is improved, but the manufacturing precision and seam quality requirements increase
Solution Approach 1:
The casing is segmented into multiple panels that are joined along abutting edge areas. The patent addresses the manufacturing precision challenges by providing guidance on panel configuration and joining methods, allowing for durable connections while managing the complexity of precise seam alignment through standardized panel designs and joining techniques.
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 configuration enhances the ball's durability, aerodynamics, and player control while maintaining a comfortable feel, as the intermediate structure effectively limits bladder expansion and tension in the casing, resulting in a more responsive and aesthetically appealing design.
Implementation Method 1
the intermediate structure includes a compressible foam layer or energy-returning rubber layer to restrict bladder expansion
Implementation Method 2
using a manufacturing process that bonds the layers through heat and pressure to create a seamless appearance
Implementation Method 3
using a manufacturing process that bonds the layers through heat and pressure to create a seamless appearance
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A sport ball may incorporate a casing that includes a plurality of joined panels. At least one of the panels may have a first layer, a second layer, and a third layer. The casing defines at least one indentation in the exterior surface, and the first layer is bonded to the third layer adjacent to the indentation. In some configurations, the casing may also define at least one indentations in a surface of the third layer, which may correspond in location with the indentation in the exterior surface. Additionally, the sport ball may include an intermediate structure and a bladder located within the casing.