Methods of forming three-dimensional panels for a game ball
First Claim
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1. A method of manufacturing a multi-layer outer panel for a game ball, the method comprising the steps of:
- a. three-dimensionally forming a generally convex top layer comprising a first material and having an outer surface and an inner surface, the outer surface of the top layer dimensioned to substantially correspond to a section of a surface of the ball; and
b. three-dimensionally forming at least one generally convex backing layer comprising a second material and having an outer surface and an inner surface,wherein the inner surface of the top layer is connected to the outer surface of the at least one backing layer, thereby forming the outer panel wherein the outer panel has a predetermined radius of curvature substantially matching a radius of the game ball.
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Abstract
A method of manufacturing a multi-layer outer panel for a game ball includes three-dimensionally forming a top layer of an outer panel, as well as one or more backing materials disposed underneath the top layer, into a shape substantially corresponding to the surface of the ball. Multi-layer outer panels are then attached to or interconnected to surround an inflatable bladder, thereby producing a game ball while minimizing overstretching of the outer material or the backing material and improving resistance of the outer panels to delamination.
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Citations
27 Claims
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1. A method of manufacturing a multi-layer outer panel for a game ball, the method comprising the steps of:
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a. three-dimensionally forming a generally convex top layer comprising a first material and having an outer surface and an inner surface, the outer surface of the top layer dimensioned to substantially correspond to a section of a surface of the ball; and b. three-dimensionally forming at least one generally convex backing layer comprising a second material and having an outer surface and an inner surface, wherein the inner surface of the top layer is connected to the outer surface of the at least one backing layer, thereby forming the outer panel wherein the outer panel has a predetermined radius of curvature substantially matching a radius of the game ball. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22)
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23. A method for manufacturing a game ball, the method comprising the steps of:
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providing an air-impermeable bladder having a substantially spherical shape; providing a plurality of multi-layer panels, each panel being formed in a generally convex shape prior to being interconnected with adjacent panels over the bladder and comprising; a generally convex top layer comprising a first material and having an outer surface and an inner surface, the outer surface of the top layer dimensioned to substantially correspond to a section of a surface of the ball, and at least one generally convex backing layer comprising a second material and having an outer surface and an inner surface, the outer surface of the at least one three-dimensional backing layer connected to the inner surface of the top layer; and interconnecting the edges of the panels, thereby forming an outer layer of the ball surrounding the bladder wherein the outer layer comprises a self-supporting structure. - View Dependent Claims (24, 25, 26)
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27. A method for manufacturing a game ball, the method comprising the steps of:
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providing an air-impermeable elastic bladder having a substantially spherical shape; providing a plurality of multi-layer panels, each panel being formed in a generally convex shape prior to being interconnected with adjacent panels over the bladder and comprising; a generally convex top layer comprising a first material and having an outer surface and an inner surface, the outer surface of the top layer dimensioned to substantially correspond to a section of a surface of the ball, and at least one generally convex backing layer comprising a second material and having an outer surface and an inner surface, the outer surface of the at least one three-dimensional backing layer connected to the inner surface of the top layer; and
interconnecting the edges of the panels, thereby forming an outer layer of the ball surrounding the bladder, wherein the ball is inflatable and a radius of the game ball in an inflated state exceeds a radius of curvature of each of the plurality of panels in an unloaded state.
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Specification