Sport Ball Indented Polymer Casing Welding
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Solution Overview
Problem
Conventional sport balls lack efficient manufacturing processes and performance enhancements, particularly in terms of aerodynamics and control, due to their traditional stitching and adhesive-based seam construction, which are time-consuming and heavy.
Innovation Solution
The sport ball features a casing formed from polymer materials with integrated polymer foam layers and indentations, bonded using a welding process that reduces mass and enhances manufacturing efficiency, while the indentations improve aerodynamics and control through a layered structure and patterned design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional stitching and adhesive-based seam construction is used, then the ball structure is stable, but the manufacturing process is time-consuming and the ball is heavy
Solution Approach 1:
The patent replaces traditional mechanical stitching and adhesive bonding processes with a welding process that joins polymer panels directly. This substitution eliminates the need for separate stitching or gluing operations, significantly reducing manufacturing time and improving productivity while maintaining structural stability.
Solution Approach 2:
The patent combines multiple manufacturing operations (panel joining and seam creation) into a single welding process. By merging these steps, the manufacturing process becomes more efficient and less time-consuming, directly addressing the contradiction between productivity and manufacturing time.
2Weight of moving object
If traditional stitching and adhesive-based seam construction is used, then the ball structure is stable, but the ball is heavy
Solution Approach 1:
The patent replaces mechanical stitching and adhesive bonding with a welding process that creates direct polymer-to-polymer bonds. This eliminates the need for additional materials like thread and adhesive, reducing the ball's overall mass while maintaining or improving structural stability through the welding joints.
Solution Approach 2:
The patent uses composite polymer structures where multiple polymer panels are welded together to form a integrated casing. This composite construction reduces weight compared to traditional single-material constructions with stitching and adhesives, while the multi-layer polymer structure provides enhanced structural stability.
3Ease of operation
If indentations are added to the ball surface, then aerodynamics and control are improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates indentations into the panel design before the welding process. By preparing the panels with pre-formed indentations and then welding them together, the manufacturing process remains relatively simple while achieving the desired aerodynamic and control performance benefits.
Solution Approach 2:
The patent applies indentations to specific locations on the ball surface where they provide the most benefit for aerodynamics and control. This localized approach allows performance enhancement without requiring complex indentations across the entire ball surface, thus limiting manufacturing complexity.
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 solution results in a lighter, more aerodynamic, and easier-to-manufacture sport ball with improved control and performance characteristics, achieved through the use of a welded polymer foam structure and patterned indentations.
Implementation Method 1
bonded using a welding process that reduces mass and enhances manufacturing efficiency
Data Source
AI summary
A sport ball includes a casing formed from a plurality of panels joined together at a plurality of seams. Each of the plurality of panels includes (a) a first layer having a first thickness, formed from a polymer material, and positioned to form a portion of an exterior surface of the sport ball; (b) a second layer having a second thickness, formed from a polymer foam material, and positioned inward and adjacent to the first layer; and (c) a third layer positioned inward and adjacent to the second layer. The first layer defines a first indentation therein. The first layer is bonded directly to the third layer at the first indentation, and the first indentation has a first indentation thickness equal to a sum of the first thickness and the second thickness. The sport ball also includes a bladder located within the casing.