U.S. patent application number 12/690371 was filed with the patent office on 2011-07-21 for inner bladder structure for ball.
This patent application is currently assigned to Long Way Enterprise Co., Ltd.. Invention is credited to Mei Sun Lin.
Application Number | 20110177895 12/690371 |
Document ID | / |
Family ID | 44277961 |
Filed Date | 2011-07-21 |
United States Patent
Application |
20110177895 |
Kind Code |
A1 |
Lin; Mei Sun |
July 21, 2011 |
INNER BLADDER STRUCTURE FOR BALL
Abstract
A ball inner bladder structure, particularly suitable for a
seamless ball, includes a bladder in the form of a spherical bag, a
yarn layer enclosing the bladder, an emulsion layer applied over
the yarn layer, and a ball cover layer bonded to the emulsion
layer. The yarn layer is an integrally knitted web structure having
a 3D spherical shape. Knitted yarns subjected to pressure can
displace relative to one another to finely adjust a surface
configuration of the web structure for the same to completely bear
against the bladder. The emulsion layer fills up voids on the yarn
layer to provide a smooth spherical surface. The specifically
knitted yarn layer can effectively control an expansion degree of
the bladder when the same is inflated. And, expansion or
compression pressure applied to the bladder is uniformly
distributed over interlocking points of knitted yarns, preventing
the bladder from deformation and breaking.
Inventors: |
Lin; Mei Sun; (Taipei,
TW) |
Assignee: |
Long Way Enterprise Co.,
Ltd.
Taipei
TW
|
Family ID: |
44277961 |
Appl. No.: |
12/690371 |
Filed: |
January 20, 2010 |
Current U.S.
Class: |
473/605 |
Current CPC
Class: |
A63B 2209/023 20130101;
D04B 1/22 20130101; A63B 2209/00 20130101; D04B 1/106 20130101;
A63B 41/02 20130101; A63B 45/00 20130101 |
Class at
Publication: |
473/605 |
International
Class: |
A63B 41/02 20060101
A63B041/02 |
Claims
1. An inner bladder structure for ball, particularly suitable for a
seamless ball, comprising a bladder being in the form of a
spherical bag and forming a main body structure of a seamless ball,
a yarn layer being provided on an outer surface of the bladder, an
emulsion layer being provided on an outer surface of the yarn layer
to serve as a binding material, and a round and smooth ball cover
layer bonded to an outer surface of the emulsion layer; the yarn
layer being a single-layered web structure integrally knitted using
a plurality of yarns to have a three-dimensional (3D) spherical
shape with a plurality of voids formed between adjacent knitting
yarns; and the emulsion layer filling up the voids on the yarn
layer to form a complete spherical body.
2. The inner bladder structure for ball as claimed in claim 1,
wherein the web structure of the yarn layer is formed by knitting
the yarns around the bladder from a predetermined starting point on
the outer surface of the bladder, so that the web structure has a
plurality of interlocking points of the yarns and is radially
outward expanded from the starting point to gradually increase a
winding radius thereof at a fixed spacing; and wherein when the
winding radius of the web structure is equal to a radius of the
bladder, the knitting continues toward another point on the bladder
diametrically opposite to the starting point while the winding
radius of the web structure gradually decreases at the same fixed
spacing, and when the web structure is finally extended to the
diametrically opposite point on the bladder, the spherical-shaped
web structure is completed.
3. The inner bladder structure for ball as claimed in claim 2,
wherein each of the interlocking points is formed at an
intersection of four knitting yarns that are connected to one
another at the intersection and extended in four different
directions, it is therefore able to control an elongation ratio and
expansion degree at the interlocking point when the same is
subjected to stress from different directions.
4. The inner bladder structure for ball as claimed in claim 1,
wherein the ball cover layer includes an inner filler layer and an
outer cover layer; the inner filler layer being in direct contact
with and glued to the outer surface of the emulsion layer, and the
outer cover layer being formed from a plurality of panels that have
the same predetermined shape and are arranged adjoining one
another.
5. The inner bladder structure for ball as claimed in claim 4,
wherein the outer cover layer is made of thermoplastic polyurethane
(TPU), and the inner filler layer is made of ethylene vinyl acetate
(EVA).
6. The inner bladder structure for ball as claimed in claim 1,
wherein the yarn layer is formed using synthetic twist yarns.
7. The inner bladder structure for ball as claimed in claim 1,
wherein the yarn layer is in the form of a spherical-shaped knitted
fabric; the spherical-shaped knitted fabric being formed by
knitting at a fixed spacing around an axis of a preset spherical
surface, which has a radius corresponding to that of the bladder,
and the knitting being started from a preset one of the longitudes
of the preset spherical surface.
8. The inner bladder structure for ball as claimed in claim 7,
wherein the spherical-shaped knitted fabric includes a plurality of
knitting yarns, which are repeatedly bent to form a plurality of
loop portions; the loop portions being respectively extended
through a loop portion formed by a previous adjacent knitting yarn,
and then being respectively extended through by another loop
portion formed by a next adjacent knitting yarn, so that a web
structure is formed with a void formed in each loop portion and
between any two laterally adjacent loop portions.
9. The inner bladder structure for ball as claimed in claim 7,
wherein the ball cover layer includes a filler layer and an outer
cover layer; the filler layer being in direct contact and glued to
the outer surface of the emulsion layer, and the outer cover layer
being formed from a plurality of panels that have the same
predetermined shape and are arranged adjoining one another.
10. The inner bladder structure for ball as claimed in claim 9,
wherein the outer cover layer is made of thermoplastic polyurethane
(TPU), and the filler layer is made of ethylene vinyl acetate
(EVA).
11. The inner bladder structure for ball as claimed in claim 7,
wherein the yarn layer is formed using synthetic twist yarns.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an inner bladder structure
for seamless ball, and more particularly to a ball inner bladder
structure that includes a yarn layer formed in a specific knitting
and stitching manner.
BACKGROUND OF THE INVENTION
[0002] There are various types of balls. Some balls with a
relatively simple structure can include a hollow spherical body
directly molded using a rubber material. The hollow spherical body
inflated with air is swollen to form an elastic ball. For the
purpose of providing the balls with required appearance and touch,
and of easily distinguishing different types of balls from one
another, the balls can further include a multi-layer structure
having an inner bladder and an outer cover layer attached to an
outer surface of the inner bladder. The inner bladder as a main
structure for supporting the ball can be manufactured in many
different ways.
[0003] In a conventional technique for manufacturing a ball with an
inner bladder, a bladder made of a rubber material and a bonded
fabric layer together constitute a spherical structure. In the
first conventional ball manufacturing technique, a whole piece of
fabric is cut into a plurality of smaller pieces having the same
predetermined shape. The cut fabric pieces are applied with an
adhesive and then bonded to an outer surface of the rubber bladder
in a specific arrangement. After the cut fabric pieces have been
bonded to the whole outer surface of the rubber bladder, the
adhesive is heat dried and the bladder is inflated to adjust an
overall shape thereof. However, the bonded joints at the overlapped
edges of the fabric pieces have relatively weak structural
strength, and the bonded fabric layer tends to deform or have
separated fabric pieces due to a shearing action. Further, the
bonded joints have increased thickness due to the overlapped edges
of the fabric pieces and accordingly reduce the roundness of the
ball so formed.
[0004] In another conventional ball manufacturing technique, a
rubber bladder and a stitched fabric layer together constitute a
spherical structure. In this conventional ball manufacturing
technique, a whole piece of fabric is cut into a plurality of
smaller pieces having the same predetermined shape. The cut fabric
pieces are stitched together to form a spherical bag, and the
rubber bladder is inserted in the spherical bag and bonded to the
spherical bag using an adhesive material. The adhesive material is
heat dried and the rubber bladder is inflated to adjust an overall
shape thereof. With the cut fabric pieces being stitched together,
the stitched joints can have increased structural strength.
However, the stitched joints still have increased thickness to
thereby reduce the roundness of the ball so formed.
[0005] In a further conventional ball manufacturing technique, a
rubber bladder and a wound yarn layer together constitute a
spherical structure. In this conventional ball manufacturing
technique, the rubber bladder is inflated to adjust an overall
shape thereof, and then yarns coated with adhesive are randomly
wound around an outer surface of the inflated rubber bladder. When
the rubber bladder has been completely wound by the yarns to have a
yarn layer formed thereon, the adhesive is heat dried and the
overall shape of the bladder is adjusted again. With this
manufacturing technique, a ball with high roundness can be
obtained. However, since the yarns are glued to the outer surface
of the rubber bladder only by the adhesive coated on the yarns, the
wound yarn layer so formed has further reduced tensile strength and
shearing strength.
[0006] According to the above-described conventional ball
manufacturing techniques, for the purpose of maintaining or
increasing the structural strength of the ball inner bladder and of
protecting the ball inner bladder against deformation under
pressure, the outer surface of the rubber bladder is bound and
reinforced using fabric pieces or yarns. However, the overlapped
edges of the fabric pieces are not easily perfectly firmly bonded
together at the bonded joints that tend to dislocate or deviated
due to a shearing action; and the bonded or the stitched joints
have relatively increased thickness to reduce the roundness of the
ball so formed. Therefore, it is necessary to improve the
conventional inner bladder structures for ball.
SUMMARY OF THE INVENTION
[0007] A primary object of the present invention is to provide an
improved inner bladder structure for ball. The inner bladder
structure includes a yarn layer formed in a specific knitting and
stitching manner to effectively control an expansion degree of an
inflatable bladder enclosed in the yarn layer. Expansion and
compression pressure applied to the bladder is uniformly
distributed over interlocking points of knitted yarns, so that the
bladder is not easily subject to deformation and breaking.
[0008] To achieve the above and other objects, the inner bladder
structure for ball according to the present invention includes a
bladder in the form of a spherical bag for using as a main body
structure of a seamless ball, a yarn layer provided on an outer
surface of the bladder, an emulsion layer provided on an outer
surface of the yarn layer to serve as a binding material, and a
round and smooth ball cover layer bonded to an outer surface of the
emulsion layer. The yarn layer is a single-layered web structure
integrally knitted using a plurality of yarns to have a
three-dimensional (3D) spherical shape, so that a plurality of
voids is formed between adjacent knitting yarns. And, the emulsion
layer fills up the voids on the yarn layer to form a complete
spherical body.
[0009] In a preferred embodiment, the web structure of the yarn
layer is formed by knitting the yarns around the bladder from a
predetermined starting point on the outer surface of the bladder,
so that the web structure has a plurality of interlocking points of
the yarns and is radially outward expanded from the starting point
to gradually increase a winding radius thereof at a fixed spacing.
When the winding radius of the web structure is equal to a radius
of the bladder, the knitting continues toward another point on the
bladder diametrically opposite to the starting point while the
winding radius of the web structure gradually decreases at the same
fixed spacing. And, when the web structure is finally extended to
the diametrically opposite point on the bladder, a spherical-shaped
web structure is completed.
[0010] Each of the interlocking points is formed at an intersection
of four knitting yarns that are connected to one another at the
intersection and extended in four different directions, it is
therefore able to control an elongation ratio and an expansion
degree at the interlocking point when the same is subjected to
stress from different directions. The ball cover layer includes an
inner filler layer and an outer cover layer. The inner filler layer
is in direct contact with and glued to the outer surface of the
emulsion layer, and the outer cover layer is formed from a
plurality of panels that have the same predetermined shape and are
arranged adjoining one another. In a preferred embodiment, the
outer cover layer is made of thermoplastic polyurethane (TPU), the
filler layer is made of ethylene vinyl acetate (EVA), and the yarn
layer is formed using synthetic twist yarns.
[0011] In another preferred embodiment, the yarn layer is in the
form of a spherical-shaped knitted fabric. The spherical-shaped
knitted fabric is formed by knitting yarns at a fixed spacing and
around an axis of a preset spherical surface, which has a radius
corresponding to that of the bladder, and the knitting is started
from a preset one of the longitudes of the preset spherical
surface.
[0012] In a preferred embodiment, the spherical-shaped knitted
fabric includes a plurality of knitting yarns, which are repeatedly
bent to form a plurality of loop portions. The loop portions are
respectively extended through a loop portion formed by a previous
adjacent knitting yarn, and are then respectively extended through
by another loop portion formed by a next adjacent knitting yarn, so
that a web structure is formed with a void formed in each loop
portion and between any two laterally adjacent loop portions.
Therefore, when the spherical-shaped knitted fabric is subjected to
an external force, the knitting yarns thereof can displace relative
to one another to thereby adjust the surface configuration of the
spherical-shaped knitted fabric.
[0013] The inner bladder structure for ball according to the
present invention is characterized in that the yarn layer is formed
in a specific knitting and stitching manner to have few or no
seams, so that the yarn layer can effectively control the expansion
degree of the bladder when the same is inflated. Moreover, when the
bladder is inflated to expand or is compressed under an external
force, pressure from such expansion or compression is uniformly
distributed over the interlocking points of yarns on the yarn
layer, so that the bladder is not easily subject to deformation and
breaking.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] 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
[0015] FIG. 1 is a cutaway view of a ball with an inner bladder
structure according to a preferred embodiment of the present
invention;
[0016] FIG. 2 schematically shows the forming of a yarn layer over
a bladder by knitting yarns on an outer surface of the bladder from
a preset starting point on the bladder;
[0017] FIG. 3 shows the knitting of the yarn layer on the outer
surface of the bladder toward another point diametrically opposite
to the starting point;
[0018] FIG. 4 shows the yarn layer over the bladder is competed and
cast off at the opposite point;
[0019] FIG. 5 is a perspective view showing the bladder is
completely covered by the knitted yarn layer;
[0020] FIG. 6 shows an emulsion layer is applied on an outer
surface of the yarn layer;
[0021] FIG. 7 shows a ball cover layer is bonded to an outer
surface of the emulsion layer shown in FIG. 6;
[0022] FIG. 8 is a perspective view showing a spherical-shaped
knitted fabric for forming the yarn layer of an inner bladder
structure according to a second embodiment of the present
invention;
[0023] FIG. 9 is an enlarged view of the circled area A of FIG.
8;
[0024] FIG. 10 shows a bladder is inserted in the spherical-shaped
knitted fabric of FIG. 8;
[0025] FIG. 11 shows the spherical-shaped knitted fabric of FIG. 10
is closed by stitching;
[0026] FIG. 12 shows two locating sections are removed from the
closed spherical-shaped knitted fabric; and
[0027] FIG. 13 is an enlarged view of the circled area B of FIG.
12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] The present invention will now be described with some
preferred embodiments thereof. For the purpose of easy to
understand, elements that are the same in the preferred embodiments
are denoted by the same reference numerals.
[0029] Please refer to FIG. 1 that is a cutaway view of a ball with
an inner bladder structure according to a first embodiment of the
present invention. The inner bladder structure according to the
present invention is particularly suitable for a seamless ball. In
the illustrated first embodiment, the inner bladder structure for
ball includes a bladder 10, a yarn layer 11, an emulsion layer 12,
and a ball cover layer 13. The bladder 10 is in the form of a
spherical bag and forms a main body structure of a seamless ball.
The spherical bag can be inflated to form a spherical body.
[0030] Please refer to FIG. 2. In the first embodiment of the
present invention, the yarn layer 11 is a single-layered web
structure integrally knitted using knitting yarns 112 to have a
three-dimensional (3D) spherical shape, so that the web structure
bearing on an outer surface of the bladder 10 has minimized seams.
A plurality of voids 113 is formed between adjacent knitting yarns
112, so that the knitting yarns 112 subjected to an externally
applied force are displaceable relative to one another, allowing
the web structure to finely adjust its surface shape and completely
bear against the outer surface of the bladder 10 to ensure the
highest possible roundness of the bladder 10. The emulsion layer 12
fills up all the voids 113 on the yarn layer 11 to form a smooth
spherical body.
[0031] In a preferred embodiment, the web structure of the yarn
layer 11 is formed by knitting the yarns 112 around the bladder 10
from a predetermined starting point 110 on the outer surface of the
bladder 10, so that the web structure has a plurality of
interlocking points 111 of the knitting yarns 112 and is radially
outward expanded from the starting point 110 to gradually increase
a winding radius thereof at a fixed spacing. Then, when the winding
radius of the web structure is equal to a radius of the bladder 10,
the knitting continues toward another point on the bladder 10
diametrically opposite to the starting point 110 while the winding
radius of the web structure gradually decreases at the same fixed
spacing. And, when the web structure is finally extended to the
diametrically opposite point on the bladder 10, the
spherical-shaped web structure is completed.
[0032] Please refer to FIG. 3. In the illustrated first embodiment,
each of the interlocking points 111 is formed at an intersection of
four knitting yarns 112 that are connected to one another at the
intersection and extended in four different directions. In this
manner, it is able to control an elongation ratio and an expansion
degree at the interlocking point 111 when the same is subjected to
stress from different directions. However, it is understood the
above embodiment is illustrated only as an exemplification and is
not intended to restrict the present invention. That is, the
interlocking point 111 may be otherwise formed at an interaction of
more than four knitting yarns 112.
[0033] The yarn layer 11 is formed using synthetic twist yarns.
With the yarn layer 11, pressure from internal expansion and
external compression can be uniformly distributed over the bladder
10, so that the bladder 10 is protected against deformation or
breaking under such pressure.
[0034] The ball cover layer 13 is glued to an outer surface of the
emulsion layer 12, and includes an inner filler layer 14 and an
outer cover layer 15. The inner filler layer 14 is in direct
contact with and glued to the outer surface of the emulsion layer
12. The outer cover layer 15 is formed from a plurality of panels
that have the same predetermined shape and are arranged adjoining
one another. In a preferred embodiment, the outer cover layer 15 is
made of thermoplastic polyurethane (TPU), and the inner filler
layer 14 is made of ethylene vinyl acetate (EVA).
[0035] Please refer to FIG. 8. According to a second embodiment of
the present invention, the yarn layer 11 is in the form of a
spherical-shaped knitted fabric 20. The spherical-shaped knitted
fabric 20 is formed by knitting yarns at a fixed spacing around an
axis of a preset spherical surface, which has a radius
corresponding to that of the bladder 10, and the knitting is
started from a preset one of the longitudes of the preset spherical
surface. The spherical-shaped knitted fabric 20 is knitted using an
elastic 3D knitting technique, and has a locating section 21 formed
at each of two opposing edges thereof. A releasable connecting yarn
22 is provided between each of the locating sections 21 and the
spherical-shaped knitted fabric 20 to form a separable joint 221
thereat, so as to facilitate later separating of the locating
sections 21 from the spherical-shaped knitted fabric 20.
[0036] FIG. 9 is an enlarged view of the circled area A of FIG. 8.
As shown, in the illustrated second embodiment of the present
invention, the spherical-shaped knitted fabric 20 includes a
plurality of knitting yarns 112, which are repeatedly bent to form
a plurality of loop portions 116. The loop portions 116 are
respectively extended through a loop portion 116 formed by a
previous adjacent knitting yarn 112, and are then respectively
extended through by another loop portion 116 formed by a next
adjacent knitting yarn 112, so that a web structure is formed with
a void 113 formed in each loop portion 116 and between any two
laterally adjacent loop portions 116. With this structure, when the
spherical-shaped knitted fabric 20 is subjected to an external
force, the knitting yarns 112 can displace relative to one another
to thereby adjust the surface configuration of the spherical-shaped
knitted fabric 20.
[0037] Please refer to FIGS. 2 to 7. To produce the inner bladder
structure for ball according to the first embodiment of the present
invention, first prepare yarns and knit the same into the
spherical-shaped yarn layer 11. An elastic opening 115 is formed at
a cast-off end of the spherical-shaped yarn layer 11 with a length
of yarn 114 extended from and left at the elastic opening 115.
Then, insert the bladder 10 in the yarn layer 11 via the elastic
opening 115 and inflate the bladder 10, so that the bladder 10 has
an outer surface tightly contacting with the yarn layer 11. Then,
the elastic opening 115 is closed and held in place by knitting the
length of yarn 114 thereat. Then, apply the emulsion layer 12 on
the outer surface of the yarn layer 11 to fill up the voids 113 on
the yarn layer 11. The emulsion layer 12 is then heat dried, and a
complete and smooth spherical structure is obtained. Finally, the
ball cover layer 13, which is formed from an upper and a lower half
ball cover, is bonded to the outer surface of the emulsion layer 12
through thermosetting to thereby form a seamless ball.
[0038] Please refer to FIGS. 10 to 13. To produce the inner bladder
structure for ball according to the second embodiment of the
present invention, in which the yarn layer 11 is in the form of a
spherical-shaped knitted fabric 20, first position the inflated
bladder 10 in a space defined by the spherical-shaped knitted
fabric 20 and then pull the spherical-shaped knitted fabric 20 for
the same to tightly contact with the outer surface of the bladder
10. Then, the two opposing edges of the spherical-shaped knitted
fabric 20 are stitched together using a stitching yarn 23, and the
releasable connecting yarns 22 are removed to separate the locating
sections 21 from the spherical-shaped knitted fabric 20. When the
spherical-shaped knitted fabric 20 is subjected to an external
force, the knitting yarns 112 can displace relative to one another
to thereby adjust the surface configuration of the spherical-shaped
knitted fabric 20, allowing the spherical-shaped knitted fabric 20
to fitly bear against the outer surface of the bladder 10.
[0039] After the spherical-shaped knitted fabric 20 has fitly
attached to the outer surface of the bladder 10, the emulsion layer
12 is applied over the outer surface of the spherical-shaped
knitted fabric 20 to fill up the voids 113 thereof in the same way
as that shown in FIG. 6. The emulsion layer 12 is then heat dried,
and a complete and smooth spherical structure is obtained. Finally,
the ball cover layer 13, which is formed from an upper and a lower
half ball cover, is bonded to the outer surface of the emulsion
layer 12 through thermosetting to thereby form a seamless ball.
[0040] In brief, in the inner bladder structure for ball according
to the present invention, the yarn layer is formed by knitting and
stitching in a specific manner to effectively control the expansion
degree of the bladder when the same is inflated. In addition, when
the bladder is inflated to expand or is compressed under an
external force, the pressure from such expansion or compression is
uniformly distributed over the interlocking points, so that the
bladder is not easily subject to deformation and breaking.
[0041] The present invention has been described with some preferred
embodiments thereof and it is understood that many changes and
modifications in the described embodiments 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.
* * * * *