Systems and methods for producing a sports ball

• US 10,328,315 B2
• Filed: 10/29/2018
• Issued: 06/25/2019
• Est. Priority Date: 10/30/2017
• Status: Active Grant

• Current Assignee: Ali Hasnain Hussain
• Original Assignee: Ali Hasnain Hussain
• Inventors: Hussain, Ali Hasnain
• Primary Examiner(s): Vaughan, Jason L
• Application Number:
  US16/173,363
• Publication Number:
  US 20190099644A1
• Time in Patent Office: 239 Days
• Field of Search: 473604, 473600
• CPC Class Codes: A63B 2243/0025 Football American football A63B2243/007
• CPC Class Codes: A63B 41/08 Ball covers; Closures therefor
• CPC Class Codes: A63B 41/10 Bladder and cover united
• CPC Class Codes: A63B 43/00 Balls with special arrangements
• CPC Class Codes: A63B 45/00 Apparatus or methods for manufacturing balls working of plastics or substances in a plastic state B29
• CPC Class Codes: B29D 22/04 Spherical articles, e.g. balls B29D22/02 takes precedence
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A method for manufacturing sports ball having a high-performance cover formed from a plurality of panels with foam provided internally.

Claims

1. A manufacturing method of a sports ball, comprising the steps of:

forming a cover of the sports ball, comprising;

a. cutting outer layer cutouts from an outer layer for a plurality of panels, the outer layer consisting at least of a fabric and one of ethylene propylene diene monomer (EPDM) foam, Ethylene Vinyl Acteate (EVA), or synthetic leather;

b. creating a bladder valve panel by inserting a valve in one of the outer layer cutouts and attaching a bladder to it;

c. determining attachment lines on each of the outer layer cutouts, the attachments lines at a distance of 2 to 6 mm from edges of each of the outer layer cutouts;

d. connecting the outer layer cutouts together using machine stitching or using glue at the attachment lines;

e. inverting the cover inside out so that the bladder and respective inner surfaces of the outer layer cutouts are within the cover; and

f. hand stitching or applying glue to any remaining unattached attachment lines;

placing the cover in a mold;

forming a solid cellular foam within the bladder by inserting a plurality of liquids though the valve, the plurality of liquids comprising of polyol polyether and isocynates; and

solidifying shape of the cover and the foam by applying heat to the cover in the mold.

2. The method of claim 1, further comprising:

inserting air with a pressure of two to nine pounds per square inch with the cover.

3. The method of claim 2, wherein forming the solid cellular foam within the bladder by inserting the plurality of liquids though the valve comprises inserting the polyol polyether and the isocyanates with the mixing ratio of 3:

1.

4. The method of claim 1, wherein forming the solid cellular foam within the bladder by inserting the plurality of liquids though the valve comprises inserting the polyol polyether and the isocyanates with a mixing ratio in a range of 1:

1 to 3;

1.

5. A manufacturing method of a sports ball, comprising the steps of:

forming a cover of the sports ball, comprising;

a. cutting outer layer cutouts from an outer layer for a plurality of panels, the outer layer consisting at least of a fabric and one of ethylene propylene diene monomer (EPDM) foam, Ethylene Vinyl Acteate (EVA), or synthetic leather;

b. creating a valve panel by inserting a valve in one of the outer layer cutouts;

c. determining attachment lines on each of the outer layer cutouts, the attachments lines at a distance of 2 to 6 mm from edges of each of the outer layer cutouts;

d. connecting the outer layer cutouts together using machine stitching or using glue at the attachment lines;

e. inverting the cover inside out so that respective inner surfaces of the outer layer cutouts are within the cover; and

f. hand stitching or applying glue to any remaining unattached attachment lines;

placing the cover in a mold;

forming a solid cellular foam within the cover by inserting a plurality of liquids though the valve, the plurality of liquids comprising of polyol polyether and isocynates; and

solidifying shape of the cover and the foam by applying heat to the cover in the mold.

6. The method of claim 5, wherein forming the solid cellular foam within the cover by inserting the plurality of liquids though the valve comprises inserting the polyol polyether and the isocyanates with a mixing ratio in a range of 1:

1 to 3;

1.

7. The method of claim 6, wherein forming the solid cellular foam within the cover by inserting the plurality of liquids though the valve comprises inserting the polyol polyether and the isocyanates with the mixing ratio of 3:

1.