Sport balls and methods of manufacturing the sport balls
First Claim
1. A method of manufacturing a sport ball, the method comprising:
- providing a plurality of panel elements that include a thermoplastic polymer material;
joining the panel elements to each other, thereby forming a casing;
turning the casing inside-out through an opening formed between a first edge and a second edge of at least two of the panel elements, such that the casing forms an exposed exterior surface of the sport ball;
forming the first edge to have a projection that extends outward from the first edge;
locating the projection under the second edge; and
joining the first edge and the second edge to each other;
wherein the step of joining the first edge and the second edge includes welding the projection to the second edge; and
locating a supplemental layer under the first edge and the second edge;
wherein the step of joining the first edge and the second edge includes joining the supplemental layer to the panel elements that form the first edge and the second edge; and
wherein the step of joining the supplemental layer to the panel elements includes welding the supplemental layer to the panel elements.
1 Assignment
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Accused Products
Abstract
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 a rounded configurations. The sport ball may also include an intermediate layer and a bladder within the casing.
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Citations
15 Claims
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1. A method of manufacturing a sport ball, the method comprising:
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providing a plurality of panel elements that include a thermoplastic polymer material; joining the panel elements to each other, thereby forming a casing; turning the casing inside-out through an opening formed between a first edge and a second edge of at least two of the panel elements, such that the casing forms an exposed exterior surface of the sport ball; forming the first edge to have a projection that extends outward from the first edge; locating the projection under the second edge; and joining the first edge and the second edge to each other; wherein the step of joining the first edge and the second edge includes welding the projection to the second edge; and locating a supplemental layer under the first edge and the second edge; wherein the step of joining the first edge and the second edge includes joining the supplemental layer to the panel elements that form the first edge and the second edge; and wherein the step of joining the supplemental layer to the panel elements includes welding the supplemental layer to the panel elements. - View Dependent Claims (2, 3, 4, 5, 6, 7)
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8. A method of manufacturing a sport ball, the method comprising:
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providing a plurality of panel elements that include a thermoplastic polymer material; welding the panel elements to each other to join the panel elements, thereby forming a casing; turning the casing inside-out through an opening formed between a first edge and a second edge of at least two of the panel elements; inserting an intermediate layer having a limited degree of stretch and an inflatable bladder into the casing through the opening, such that the casing forms an exposed exterior surface of the sport ball; locating a supplemental layer under the first edge and the second edge, the supplemental layer having an inner-facing surface and an opposing outer-facing surface wherein the step of locating the supplemental layer under the first edge and the second edge includes positioning the outer-facing surface of the supplemental layer against an inner-facing surface of the casing; locating the first edge and the second edge adjacent to each other and in contact with each other; joining the supplemental layer to the panel elements that form the first edge and the second edge; and welding the first edge and the second edge to each other; wherein the step of joining the supplemental layer to the panel elements includes welding the supplemental layer to the panel elements. - View Dependent Claims (9, 10, 11)
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12. A method of manufacturing a sport ball, the method comprising:
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providing a plurality of panel elements that include a thermoplastic polymer material; performing a first manufacturing process including welding the panel elements to each other to join the panel elements, thereby forming a casing, wherein the first manufacturing process includes welding protruding flanges at the periphery of each panel element to protruding flanges of adjacent panel elements; turning the casing inside-out through an opening formed between a first edge and a second edge of at least two of the panel elements; inserting an intermediate layer having a limited degree of stretch and an inflatable bladder into the casing through the opening, such that the casing forms an exposed exterior surface of the sport ball; forming the first edge to have a projection that extends outward from the first edge, and locating the projection under the second edge; and performing a second manufacturing process including joining the first edge and the second edge to each other; wherein the step of joining the first edge and the second edge to each other includes welding the first edge to the second edge; wherein the second manufacturing process includes a step of locating a supplemental layer under the first edge and the second edge, and the step of joining the first edge to the second edge includes joining the supplemental layer to the panel elements that form the first edge and the second edge; and wherein joining the supplemental layer to the panel elements includes welding the supplemental layer to the panel elements independently of the intermediate layer. - View Dependent Claims (13, 14, 15)
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Specification