Sport Ball Panel Welding and Backing Layer Assembly
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Solution Overview
Problem
Conventional inflatable sport balls face challenges in manufacturing efficiency and mass distribution due to the time-consuming stitching process and the mass contributed by stitched seams, which can be improved by adopting a welding process for joining panels.
Innovation Solution
The sport ball design incorporates a welding process to join polymer panels, reducing the number of seams and utilizing the saved mass for enhancing performance properties, and includes a backing layer with an opening for inserting a bladder and closure panel, allowing for efficient assembly and closure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If stitching process is used to join panels, then panels can be joined together, but manufacturing time increases and mass at seams increases
Solution Approach 1:
The patent replaces the mechanical stitching process with a welding process to join panels. The welding process uses heat and pressure to fuse panels together, eliminating the need for needles, thread, and complex stitching operations. This substitution significantly reduces manufacturing time while maintaining panel joining functionality.
Solution Approach 2:
The patent changes the joining parameters from mechanical (stitching with needles and thread) to thermal and pressure-based (welding). By altering the fundamental parameters of the joining process, the patent achieves faster manufacturing without compromising the structural integrity of panel joints.
2Ease of manufacture
If stitching process is used to join panels, then panels can be joined together, but mass at seams increases
Solution Approach 1:
The welding process eliminates the need for stitching materials such as thread and reinforced seam structures. By fusing panels directly through heat and pressure, the joining process removes excess mass that would otherwise be required for mechanical stitching, resulting in lighter seams and overall ball structure.
3Ease of operation
If casing is assembled inside-out with open seams, then bladder can be inserted, but closure complexity increases
Solution Approach 1:
The patent incorporates a pre-formed closure panel into the casing structure before bladder insertion. This closure panel is integrated into the panel array and positioned to automatically seal the opening once the bladder is inserted and inflated. The preliminary placement of the closure panel eliminates the need for complex post-insertion closure operations.
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 welding process decreases manufacturing time, reduces mass at seams, and enhances structural elements like energy return and durability, while the backing layer facilitates easier assembly and closure, improving the overall performance and efficiency of the sport ball.
Implementation Method 1
The sport ball design incorporates a welding process to join polymer panels
Data Source
AI summary
A sport ball may include a casing that forms an exterior surface of the sport ball. The casing may incorporate a plurality of joined panels, including a closure panel. In addition, the ball may include a backing layer located radially inward of the closure panel, the backing layer extending beyond a peripheral boundary of the closure panel and at least partially overlapping with one or more panels adjacent to the closure panel. The backing layer may also include an opening located radially inward of the closure panel, the opening being smaller than the surface area of the closure panel. Also, the ball may include a bladder located radially inward of the backing layer, the bladder including a valve for introducing fluid into the ball, the valve extending through the opening and through the closure panel.