U.S. patent application number 12/649131 was filed with the patent office on 2010-07-01 for seamless ball structure.
This patent application is currently assigned to Long Way Enterprise Co., Ltd. Invention is credited to Mei Sun LIN.
Application Number | 20100167850 12/649131 |
Document ID | / |
Family ID | 41233325 |
Filed Date | 2010-07-01 |
United States Patent
Application |
20100167850 |
Kind Code |
A1 |
LIN; Mei Sun |
July 1, 2010 |
SEAMLESS BALL STRUCTURE
Abstract
A seamless ball structure, particularly suitable for balls used
in different ball games, such as soccer, volleyball and basketball,
includes an inner bladder, and an inner yarn layer, an emulsion
layer and an outer cover layer sequentially provided on an outer
surface of the inner bladder from inner to outer side. The emulsion
layer inwardly permeates into voids among the yarns of the inner
yarn layer. The outer cover layer is attached at an inner fabric
layer thereof to an outer surface of the emulsion layer. The
emulsion layer being heated and pressurized is in an adhering state
to sufficiently tightly attach to the inner yarn layer and the
outer cover layer, giving the ball so formed an increased
structural strength. The ball can be easily and quickly
manufactured at reduced manufacturing cost to thereby provide an
improved ball structure that does not require any sewing with
threads.
Inventors: |
LIN; Mei Sun; (Taipei,
TW) |
Correspondence
Address: |
RABIN & Berdo, PC
1101 14TH STREET, NW, SUITE 500
WASHINGTON
DC
20005
US
|
Assignee: |
Long Way Enterprise Co.,
Ltd
Taipei
TW
|
Family ID: |
41233325 |
Appl. No.: |
12/649131 |
Filed: |
December 29, 2009 |
Current U.S.
Class: |
473/605 |
Current CPC
Class: |
A63B 45/00 20130101;
A63B 41/02 20130101; A63B 2243/0025 20130101; A63B 2243/0037
20130101; A63B 2243/0095 20130101; A63B 41/00 20130101 |
Class at
Publication: |
473/605 |
International
Class: |
A63B 41/00 20060101
A63B041/00 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 30, 2008 |
CN |
200820182593.8 |
Claims
1. A seamless ball structure, comprising: an inner bladder forming
a center of the ball structure; an inner yarn layer being wound
around an outer surface of the inner bladder; an emulsion layer
being applied to an outer surface of the inner yarn layer; and an
outer cover layer being attached to an outer surface of the
emulsion layer.
2. The seamless ball structure as claimed in claim 1, wherein the
outer cover layer is further applied on an inner surface thereof
with another emulsion layer.
3. The seamless ball structure as claimed in claim 1, wherein the
ball structure is heated and pressurized after the outer cover
layer is attached to the outer surface of the emulsion layer, so
that the emulsion is in an adhering state.
4. The seamless ball structure as claimed in claim 1, wherein the
outer cover layer includes at least: an inner fabric layer for
inwardly directly attaching to the emulsion layer; a seamless outer
layer being formed of a plurality of identically shaped pieces,
which are orderly placed adjacent to one another to complete the
seamless outer layer; and a filling material being sandwiched
between the inner fabric layer and the seamless outer layer.
5. The seamless ball structure as claimed in claim 4, wherein the
seamless outer layer is made of a thermoplastic polyurethane
material (TPU), and the filling material is ethylene vinyl acetate
(EVA).
Description
FIELD OF THE INVENTION
[0001] The present invention relates to a seamless ball structure,
and more particularly to a seamless ball structure advantageously
suitable for balls of different ball games, such as soccer,
volleyball and basketball.
BACKGROUND OF THE INVENTION
[0002] Conventionally, most of the balls for use in sports games or
recreational activities, such as soccer and volleyball, have a
structure including a rubber-made inner bladder forming a center of
the ball and wrapped around by an outer cover formed of a canvas
fabric.
[0003] Please refer to FIG. 1 that shows a first conventional ball
structure, which includes an inner bladder 10, an inner sewed layer
11, and an outer sewed layer 12. To manufacture the first
conventional ball structure, first cut the canvas fabric into a
plurality of identical and specifically shaped pieces. Then, apply
an adhesive 13 on an inner surface of the pieces of the sew-up
outer layer 12 for the same to attach to the pieces of the inner
sewed layer 11. Further, the adhesive 13 is dried with heat, and
the adhered pieces of inner and outer sewed layers are sewed
together to form a bag-shaped body, which is then turned inside out
for receiving the inner bladder 10 therein before being sealed and
inflated into a desired shape.
[0004] In the above-described conventional ball structure, the
joints of any two adjacent pieces, that is, the seams 14 on the
ball are subject to deformation when being pulled, bringing sewing
threads thereat to gradually expose to external environment and
even become broken when the ball has been used over a long time.
The inner and outer sewed layers 11, 12 are usually made of canvas,
which prevents the inner and outer sewed layers 11, 12 from being
easily firmly attached to one another in the adhering process.
Further, as a result of shearing action, the inner and the outer
sewed layer 11, 12 tend to dislocate from each other and become
skewed.
[0005] FIG. 2 shows a second conventional ball structure, which
includes an inner bladder 20, an inner yarn layer 21, and an outer
sewed layer 22. A filling material 24 is first provided to an inner
side the outer sewed layer 22, and then, an adhesive 23 is applied
on an inner surface of the filling material 24 to thereby attach
the outer sewed layer 22 to the inner yarn layer 21. In the second
conventional ball structure, the inner yarn layer 21 is used to
replace the inner sewed layer 11 in the first conventional ball
structure, and the filling material 24 is provided to increase an
overall thickness and accordingly, a structural strength of the
ball to avoid possible deformation and breaking thereof. While the
second ball structure is structurally strengthened, the sewed outer
layer 22 thereof is still subject to the same problem as in the
first conventional ball structure shown in FIG. 1. Further, since
the second conventional ball structure has joints or seams 25 that
have a reduced thickness compared to the seams 14 in the first
conventional ball structure, the seams 25 are more easily deformed
and broken under a shearing force.
[0006] FIG. 3 shows a third conventional ball structure, which
includes an inner bladder 30, an inner sewed layer 31, an outer
sewed layer 32 adhered to the inner sewed layer 31 using an
adhesive 33, and an outer cover layer 35. The outer cover layer 35
is adhered to an outer surface of the outer sewed layer 32 in a
staggered relation, so that seams 34 on the outer sewed layer 32
are not exposed to the external environment. While the outer cover
layer 35 increases the overall thickness and the structural
strength of the third conventional ball structure, the inner sewed
layer 31 and the outer sewed layer 32 are still subject to the same
problem as the first conventional ball structure shown in FIG. 1.
That is, the seams 34 tend to deform or break and therefore form
bumps on the surface of the ball, making the ball not suitable for
use.
[0007] As can be seen from the above description, in addition to
their respective disadvantages, all the three conventional ball
structures have the problems caused by the sewed inner and outer
layers, such as deformed and broken sewing threads due to shearing
stress applied thereto. It is therefore desirable to improve such
problems.
SUMMARY OF THE INVENTION
[0008] A primary object of the present invention is to provide a
seamless ball structure that has increased structural strength and
overcomes the problem of deformed and broken sewing threads as
found in the conventional ball structures.
[0009] Another object of the present invention is to provide a
seamless ball structure that can be easily and quickly manufactured
at reduced manufacturing cost.
[0010] To achieve the above and other objects, the seamless ball
structure according to the present invention includes an inner
bladder forming a center of the ball structure; an inner yarn layer
being wound around an outer surface of the inner bladder; an
emulsion layer being applied to an outer surface of the inner yarn
layer; and an outer cover layer being attached to an outer surface
of the emulsion layer.
[0011] In an operable embodiment of the present invention, the
outer cover layer is further applied on an inner surface thereof
with another emulsion layer.
[0012] In another operable embodiment of the present invention, the
ball is heated and pressurized after the outer cover layer is
attached to the emulsion layer, so that the emulsion layer is in an
adhering state.
[0013] In a preferred embodiment of the present invention, the
outer cover layer includes at least an inner fabric layer for
inwardly directly attaching to the emulsion layer; a seamless outer
layer being formed of a plurality of identically shaped pieces,
which are orderly placed adjacent to one another to complete the
seamless outer layer; and a filling material being sandwiched
between the inner fabric layer and the seamless outer layer.
[0014] In a preferred embodiment of the present invention, the
seamless outer layer is made of a thermoplastic polyurethane
material (TPU), and the filling material is ethylene vinyl acetate
(EVA).
[0015] The ball according to the present invention is formed of an
inner yarn layer, an outer cover layer and an intermediate emulsion
layer without the need of sewing adjacent segments together using
threads as in the prior art ball structures. Therefore, the ball
according to the present invention is not disadvantageously subject
to exposed or broken sewing threads under an externally applied
force, and has increased structural strength. Moreover, the ball
according to the present invention can be more easily and
efficiently manufactured at reduced manufacturing cost to thereby
provide an improved ball structure that does not require any sewing
and is seamless.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The structure and the technical means adopted by the present
invention to achieve the above and other objects can be best
understood by referring to the following detailed description of
the preferred embodiments and the accompanying drawings,
wherein
[0017] FIG. 1 is a fragmentary sectional view of a first
conventional ball structure;
[0018] FIG. 2 is a fragmentary sectional view of a second
conventional ball structure;
[0019] FIG. 3 is a fragmentary sectional view of a third
conventional ball structure;
[0020] FIG. 4 is a cutaway view of a seamless ball structure
according to a preferred embodiment of the present invention;
[0021] FIG. 5 is a fragmentary sectional view of the seamless ball
structure according to FIG. 4; and
[0022] FIG. 6 is a pictorial flow chart illustrating the steps of
manufacturing the seamless ball structure according to an operable
embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] A preferred embodiment of the present invention is now
described with more details with reference to the accompany
drawing.
[0024] Please refer to FIGS. 4 and 5. A ball 40 with the seamless
ball structure according to a preferred embodiment of the present
invention includes an inflatable inner bladder 41, which is
internally located at a center of the ball 40 and usually made of
an elastic rubber material.
[0025] On an outer surface of the inner bladder 41, an inner yarn
layer 42 having a predetermined thickness and fully attached to the
inner bladder 41 is formed by winding a plurality of yarns around
the inner bladder 41. With the inner yarn layer 42 being formed of
yarns, it is possible for the inner bladder 41 wound around by the
inner yarn layer 42 to responsively expand and contract when the
inner bladder 41 is inflated and deflated, respectively, without
becoming wrinkled or deformed to produce an unsmooth surface of the
inner bladder 41.
[0026] An emulsion prepared with a predetermined material is
applied to an outer surface of the inner yarn layer 42 to form an
emulsion layer 44 thereon. With the inner yarn layer 42 being
formed of yarns, the emulsion layer 44 applied to the inner yarn
layer 42 automatically uniformly permeates into the inner yarn
layer 42 via voids among the yarns, so that the emulsion and the
yarns have increased contact area between them.
[0027] Please refer to FIG. 6. According to the illustrated
manufacturing flowchart, the inner bladder 41 with the emulsion
layer 44 applied on the inner yarn layer 42 is immediately
positioned in a heating and pressurizing apparatus 50. The heating
and pressurizing apparatus 50 includes mutually closable upper and
lower halves to internally define an inner space corresponding to
the size and shape of the ball 40. Before positioning the
half-finished product of the ball 40 in the heating and
pressurizing apparatus 50, first orderly place a plurality of
segments of an outer cover layer 43 on a surface of the inner
space. Then, when the outer cover layer 43 is attached to the
emulsion layer 44 of the half-finished product of the ball 40
positioned in the inner space, the heating and pressuring apparatus
50 is quickly heated and pressurized. In the process of heating and
pressurizing, the emulsion layer 44 is in an adhesive state to
thereby completely tightly adhere the inner yarn layer 42 to the
outer cover layer 43. Meanwhile, the ball 40 is inflated via one
side of the heating and pressurizing apparatus 50 while the latter
is heated and pressurized, so that the ball 40 is expanded to a
desired shape.
[0028] As can be seen from FIGS. 4 and 5, the outer cover layer 43
includes, from outer to inner side, at least one seamless outer
layer 431, one filling material 432, and one inner fabric layer
433. The seamless outer layer 431 is a component directly visible
by a user, and is integrated from a plurality of shaped pieces or
segments that are placed adjacent to one another in the inner space
of the heating and pressurizing apparatus 50. When the segments are
differently shaped, they can together present different
configurations, such as the configuration of a soccer ball, a
volleyball, or a basketball. In a preferred manner of
manufacturing, the seamless outer layer 431 can be made of a
thermoplastic polyurethane material (TPU). The filling material 432
is used mainly to increase an overall thickness of the outer cover
layer 43 and to further increase the structural strength of the
ball 40, preventing the ball 40 against deformation and damage. In
a preferred manufacturing manner, the filling material 432 can
include, for example, ethylene vinyl acetate (EVA). The inner
fabric layer 433 is an innermost layer of the outer cover layer 43
for inwardly adhering to the emulsion layer 44. Generally, the
inner fabric layer 433 is formed of a fabric material with
relatively coarse surface and high friction coefficient to ensure
increased contact area between the inner fabric layer 433 and the
emulsion layer 44 and prevent the outer cover layer 43 against easy
separation from the emulsion layer 44.
[0029] In another operable embodiment of the present invention,
another layer of emulsion is first applied on the inner surface of
the outer cover layer 43 before the half-finished product of the
ball 40 is positioned in the heating and pressurizing apparatus 50,
so that both the inner yarn layer 42 on the inner bladder 41 and
the inner fabric layer 433 on the outer cover layer 43 are fully
permeated by the emulsion before they are placed in the heating and
pressurizing apparatus 50. Then, when being heated and pressurized,
the emulsion in both of the inner yarn layer 42 and the inner
fabric layer 433 is molten to firmly bind the two components to
each other, giving the ball 40 an increased structural
strength.
[0030] The ball 40 according to the present invention is formed of
an inner yarn layer, an outer cover layer and an intermediate
emulsion layer without the need of sewing adjacent segments
together using threads as in the prior art ball structures.
Therefore, the ball 40 according to the present invention is not
disadvantageously subject to exposed or broken sewing threads under
an externally applied force, and has increased structural strength.
Moreover, the ball 40 according to the present invention can be
more easily and efficiently manufactured at reduced manufacturing
cost. Thus, the ball 40 is an improved ball structure that does not
require any sewing and is therefore seamless.
[0031] The present invention has been described with a preferred
embodiment thereof and it is understood that many changes and
modifications in the described embodiment can be carried out
without departing from the scope and the spirit of the invention
that is intended to be limited only by the appended claims.
* * * * *