Game ball having a thin cover and method of making same

• US 20030203780A1
• Filed: 05/08/2003
• Published: 10/30/2003
• Est. Priority Date: 10/03/2001
• Status: Active Grant

• Current Assignee: Wilson Sporting Goods Company (Anta International Group Holdings Ltd.)
• Original Assignee: Wilson Sporting Goods Company (Anta International Group Holdings Ltd.)
• Inventors: Krysiak, Kevin L., Guenther, Douglas G.
• Granted Patent: US 7,699,727 B2
• Time in Patent Office: Days
• US Class Current: 473/604
• CPC Class Codes: A63B 41/08 Ball covers; Closures therefor
• 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: B29C 41/08 Coating a former, core or other substrate by spraying or fluidisation, e.g. spraying powder spray-up of reinforcing fibres B29C70/305
• CPC Class Codes: B29C 41/12 Spreading-out the material on a substrate , e.g. on the surface of a liquid
• CPC Class Codes: B29C 41/14 Dipping a core B29C41/10 takes precedence
• CPC Class Codes: B29C 41/20 incorporating preformed parts or layers, e.g. moulding inserts or for coating articles
• CPC Class Codes: B29C 41/36 Feeding the material on to the mould, core or other substrate
• CPC Class Codes: B29C 70/70 Completely encapsulating inserts B29C70/86 takes precedence
• CPC Class Codes: B29D 22/04 Spherical articles, e.g. balls B29D22/02 takes precedence
• CPC Class Codes: B29L 2031/54 Balls

Abstract

A game ball is formed by molding a carcass in the final shape of the ball, spraying a mold surface with cover material, inserting the carcass into the mold, and molding the cover material onto the carcass.

Claims

1. A method of making a game ball comprising the steps of:

obtaining a mold having a n inner surface defining a spherical mold cavity;

forming a spherical carcass;

spraying a cover material onto the inner surface of the mold;

inserting the carcass into the mold cavity;

closing the mold around the carcass; and

molding the cover material onto the carcass.

2. The method of claim 1 further including the step of forming the carcass by winding an inflated bladder with at least one thread.

3. The method of claim 2 wherein the step of forming the carcass includes the step of molding rubber onto the thread-wound bladder.

4. The method of claim 1 wherein the cover material is a polyurethane.

5. The method of claim 1 wherein the step of forming the carcass includes molding outwardly projecting pebbles on the outer surface of the carcass.

6. The method of claim 1 wherein the step of molding the carcass and the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.

7. A method of making a game ball comprising the steps of:

obtaining a mold having a spherical mold cavity;

forming a spherical carcass;

spraying a cover material onto the carcass; and

heating the cover material and the carcass to bond the cover material to the carcass.

8. The method of claim 7 further comprising the steps of inserting the carcass and the cover material into the spherical mold cavity of the mold, closing the mold around the carcass and the cover material;

and molding the carcass and the cover material to bond the cover material to the carcass.

9. The method of claim 7 further including the step of forming the carcass by winding an inflated bladder with at least one thread.

10. The method of claim 9 wherein the step of forming the carcass includes the step of molding rubber onto the thread-wound bladder.

11. The method of claim 7 wherein the cover material is a polyurethane.

12. The method of claim 7 wherein the step of forming the carcass includes molding outwardly projecting pebbles on the outer surface of the carcass.

13. The method of claim 7 wherein the step of molding the carcass and the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.

14. A method of making a game ball comprising the steps of:

obtaining at least one mold having a spherical mold cavity;

forming a spherical carcass;

obtaining a container sized to receive at least one spherical carcass;

placing a cover material into the container;

heating the cover material to a fluid state;

inserting the carcass into the cover material within the container;

removing the carcass with a film of cover material from the container after a predetermined period of time;

inserting the carcass with the film of cover material into the spherical mold cavity of the mold;

closing the mold around the carcass and the film of cover material; and

molding the carcass and the film of cover material to bond the cover material to the carcass.

15. The method of claim 14 wherein the step of forming a spherical carcass is performed using a first mold, and wherein the steps of:

inserting the carcass with the film of cover material into the spherical mold cavity of the mold;

closing the mold around the carcass and the film of cover material; and

molding the carcass and the film of cover material to bond the cover material to the carcass, are performed using a second mold.

16. The method of claim 14 further including the step of forming the carcass by winding an inflated bladder with at least one thread.

17. The method of claim 14 wherein the step of forming the carcass includes the step of molding at least one panel onto the thread-wound bladder.

18. The method of claim 17 wherein the at least one panel is formed of a material selected from the group consisting of butyl rubber, natural rubber, sponge rubber and combinations thereof.

19. The method of claim 14 wherein the cover material is a polyurethane.

20. The method of claim 14 wherein the step of forming the carcass includes molding outwardly projecting pebbles on an outer surface of the carcass.

21. The method of claim 14 wherein the step of molding the carcass and the film of the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.

22. A game ball comprising a spherical carcass and a one-piece cover, the cover surrounding the carcass and bonded to the carcass without an adhesive, the cover having a thickness less than 0.5 mm.

23. The game ball of claim 22 in which the cover is formed of a polyurethane.

24. The game ball of claim 22 in which the carcass includes a bladder and at least one thread wound around the bladder.

25. The game ball of claim 22 in which the carcass further includes at least one panel molded over the thread-wound bladder.

26. The game ball of claim 25 wherein the at least one panel is formed of a material selected from the group consisting of butyl rubber, natural rubber, sponge rubber and combinations thereof.