Sport Ball Panel Welding Seam Mass Reduction
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Solution Overview
Problem
Conventional sport balls have mass inefficiencies due to stitched seams and time-consuming manufacturing processes, which affect their performance and production efficiency.
Innovation Solution
The sport ball manufacturing process involves welding thermoplastic polymer panels to form seams, reducing mass and increasing efficiency, while also incorporating an intermediate layer and bladder for structure and inflation, with specific configurations for panel shapes and welding techniques to enhance durability and aerodynamics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If stitched seams are used to join panels, then the sport ball structure is durable, but the mass of seams increases and manufacturing time is consumed
Solution Approach 1:
The patent replaces the mechanical stitching system with a welding system. Panels are joined by welding their edges together, eliminating the need for threads, needles, and stitching operations. This substitution reduces seam mass while maintaining joint strength through direct material fusion, resolving the contradiction between durability and weight.
2Strength
If stitched seams are used to join panels, then the sport ball structure is durable, but the manufacturing time increases
Solution Approach 1:
The welding process replaces time-consuming mechanical stitching operations. Welding can be performed more quickly and with fewer manual steps than traditional stitching, thereby reducing manufacturing time while maintaining or improving joint durability through direct material bonding.
Solution Approach 2:
The patent changes the joining method from mechanical (stitching) to thermal/process-based (welding). This parameter change in the joining process enables faster production while achieving durable bonds, resolving the time-durability contradiction.
3Productivity
If panel edges are welded to each other, then the mass of seams is reduced and manufacturing efficiency increases, but the panel edges require specific configurations
Solution Approach 1:
The panel edges are pre-formed with specific configurations (protrusions, recesses, or geometric shapes) before the welding process. This preliminary action ensures that when panels are joined, the edges align properly and weld effectively, simplifying the actual welding operation and improving manufacturing efficiency despite the added initial forming step.
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 method reduces the mass of seams, enhances performance properties like energy return and durability, and increases manufacturing efficiency by eliminating stitched seams and streamlining the production process.
Implementation Method 1
The casing incorporates a plurality of joined panel elements that include a first panel element with a first edge and a second panel element with a second edge. In general, the first edge and the second edge are welded to each other.
Data Source
AI summary
A sport ball may include a casing that incorporates a plurality of joined panel elements, which include a first panel element with a first edge and a second panel element with a second edge. The first edge and the second edge are welded to each other. In some configurations, the first panel element has a first edge with a projection that extends outward from the first edge, the second panel element has a second edge that is located adjacent to the first edge, and the projection of the first edge is located between the second edge and the bladder. In another configuration, the first edge and the second edge are formed to have rounded configurations. The sport ball may also include an intermediate layer and a bladder within the casing.