US20150265883A1

US20150265883A1 - Game Ball and Method for Making Game Ball

Info

Publication number: US20150265883A1
Application number: US14/730,761
Authority: US
Inventors: Roy Bulfin; Frank Chang; Patrick Lepere
Original assignee: Zwyxis Hongkong Co Ltd
Current assignee: Zwyxis Hongkong Co Ltd
Priority date: 2013-09-13
Filing date: 2015-06-04
Publication date: 2015-09-24

Abstract

The invention discloses a method of making a game ball. The method comprises utilizing a mold to form a game ball section. The patterned surface is imprinted into the surface of the molded game ball section. The mold is utilized to create a plurality of grooves in the outer surface of the molded game ball section. The plurality of grooves creates a strength and resiliency in the molded game ball section. One or more molded game ball sections are combined edge to edge to create a final game ball. The mold used can be a male mold or a female mold. The molded game ball section can be made through vacuum forming, compression molding, or injection molding.

Description

PRIORITY

This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/007,436 filed on Jun. 4, 2014 and is a continuation in part of U.S. application Ser. No. 14/026,171 filed on Sep. 13, 2013.

FIELD OF THE INVENTION

This invention pertains to balls used for athletic games, and more particularly to a method of utilizing a mold for forming pieces of a game ball and securing those pieces into a complete spherical ball.

BACKGROUND OF INVENTION

Soccer balls and methods of their manufacture are well known in the art. Conventional soccer balls are constructed with a stiff polymer exterior with an internal air bladder. The covering of a ball is made of a number of panels stitched together. The thirty two panel ball consists of twenty hexagonal and twelve pentagonal surfaces. The covering is backed with multiple layers of lining of polyester or cotton blend which gives the ball its strength, structure, and bounce. A bladder is placed underneath the layers of covering to hold air. The bladders are usually made of latex rubber or butyl (rubber-like material). Most balls use valves for air retention.
A user inflates the interior bladder to the desired pressure prior to use on the field. The conventional construction presents several limitations. First, it may be difficult to obtain the desired internal pressure. If a user has a pump without a means for measuring pressure, the user may over internal bladder, making the soccer ball too stiff. Second, the internal bladder may be punctured, rendering the soccer ball flat and useless. Third, it is often difficult to achieve a consistent spherical shape during production as the shape is dependent upon the outer shell. Fourth, internal pressure is not consistent in conventional balls, either from ball to ball or during the lifetime of an individual ball. This variation in internal pressure affects the performance and response of the soccer ball during game play. What is needed is a soccer ball which does not utilize an internal inflatable bladder but still provides the proper level of pressure and response as a standard soccer ball.
Additionally, conventional soccer balls require several steps to manufacture. First the outer panel material is constructed with a layer of outer material being backed with a layer or layers of cotton or fibrous material attached via an adhesive. The material is then cut into the thirty-two panels and pre-punched with holes for stitching. The stitching is done by turning the ball inside out so none of the stitches show on the outside of the ball. The stitcher uses a guide to help in assembling the panels in the proper order. A different type of needle is used to complete the stitching of each panel so the final knot disappears. In some instances the panels are glued together rather than being stitched. The finished ball is reversed and the bladder is inserted and inflated. This process is long and tedious and involves multiple steps. What is needed is a process to form and assemble a soccer ball that only involves a few steps.

SUMMARY OF THE INVENTION

The following presents a simplified summary in order to provide a basic understanding of some aspects of the disclosed innovation. This summary is not an extensive overview, and it is not intended to identify key/critical elements or to delineate the scope thereof. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.
The invention is directed toward a method of making a game ball comprising selecting a blank of material, heating the blank of material, and putting the blank of material into a mold. The mold has a contoured face with a plurality of hexagonal shapes, a plurality of pentagonal shapes, and a plurality of border sections, each of the border sections disposed between two of the shapes. The hexagonal shapes and the pentagonal shapes are situated in a predetermined pattern. The border sections comprise a first bevel area, a second bevel area, and a groove disposed between the first bevel area and the second bevel area. The method further comprises deforming the blank of material, transferring the shape of the contoured face into the deformed blank of material, forming the deformed material into a molded game ball section, creating a plurality of pentagonal shapes in the outer surface of the molded game ball section with the contoured face of the mold, creating a plurality of hexagonal shapes in the outer surface of the molded game ball section with the contoured face of the mold, creating a plurality of border sections disposed between two shapes in the outer surface of the molded game ball section with the contoured face of the mold, creating a pair of bevel sections within each of the border sections in the outer surface of the molded game ball section with the contoured face of the mold, creating a groove disposed between each of the pair of bevel sections in the outer surface of the molded game ball section with the contoured face of the mold, cooling the molded game ball section, removing the molded game ball section from the mold, and combining the molded game ball section with one or more other molded game ball sections to form a spherical game ball.
In another embodiment of the invention the method further comprises ensuring each of the plurality of border sections molded into the outer surface of the molded game ball section is substantially twelve millimeters wide, ensuring each of the pair of bevels in the plurality of border sections molded into the outer surface of the molded game ball section is substantially 1.5 millimeters deep into the surface of the molded game ball section, ensuring each of the grooves in the plurality of border sections molded into the outer surface of the molded game ball section has a substantially triangular cross-sectional shape with an angle of sixty degrees, is substantially 0.4 millimeters wide at the surface of the molded game ball section, and is substantially 0.3 millimeters deep into the surface of the molded game ball section, and ensuring that the thickness of the molded game ball section is substantially 2.5 millimeters from the inside edge of the molded game ball section to the outer edge of each of the plurality of grooves.
The method may further comprise creating a vacuum between the contoured face of the mold and the deformed blank of material. The method may further comprise applying hydraulic pressure to the deformed blank of material to compress the deformed blank of material into the mold. The method may further comprise applying an adhesive to the edge of the molded game ball section prior to adjoining the molded game ball sections. The method may further comprise applying an adhesive to the outer surface of the spherical game ball and applying an outer layer of material to the outer surface of the spherical game ball. The method may further comprise creating one or more connectors extending from the edge of the molded game ball section with the mold and creating one or more receivers extending into the edge of the molded game ball section with the mold. The connectors of one molded game ball section are complementary to the receivers of a second game ball section. The connectors of one molded game ball section are disposed within the receivers of a second game ball section when the molded game ball sections are combined together.
The invention is also directed towards a method of making a game ball comprising heating a predetermined amount of particulate polymer material to a melting point and creating a cavity between a contoured female mold and a male mold. The female mold has a contoured face. The contoured face comprises a plurality of hexagonal shapes, a plurality of pentagonal shapes, and a plurality of border sections, each of said border sections disposed between two of the shapes. The hexagonal shapes and the pentagonal shapes are situated in a predetermined pattern. The border sections comprises a first bevel area, a second bevel area, and a groove disposed between the first bevel area and the second bevel area. The method further comprises injecting a predetermined amount of the melted polymer into the cavity, forming the melted polymer into a molded game ball section, creating a plurality of pentagonal shapes in the outer surface of the molded game ball section with the contoured face of the female mold, creating a plurality of hexagonal shapes in the outer surface of the molded game ball section with the contoured face of the female mold, creating a plurality of border sections disposed between two shapes in the outer surface of the molded game ball section with the contoured face of the female mold, creating a pair of bevel sections within each of the border sections in the outer surface of the molded game ball section with the contoured face of the female mold, creating a groove disposed between each of the pair of bevel sections in the outer surface of the molded game ball section with the contoured face of the female mold, cooling the molded game ball section, removing the male mold from the female mold, removing the molded game ball section from the female mold, and combining the molded game ball section with one or more other molded game ball sections to form a spherical game ball.
Still other embodiments of the present invention will become readily apparent to those skilled in this art from the following description wherein there is shown and described the embodiments of this invention, simply by way of illustration of the best modes suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modifications in various obvious aspects all without departing from the scope of the invention. Accordingly, the drawing and descriptions will be regarded as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of this invention will be described in detail, wherein like reference numerals refer to identical or similar components, with reference to the following figures, wherein:

FIG. 1 is a side view of a game ball mold;

FIG. 2 is a top view of a game ball mold;

FIG. 3 is a side view of a cross section of a game ball mold;

FIG. 4A is a side view of a cross section of a portion of a game ball mold;

FIG. 4B is a side view of a cross section of a portion of a game ball mold;

FIG. 5 is a perspective view of a game ball mold;

FIG. 6 is a side view of a cross section of a molded game ball section;

FIG. 7A is a side view of a portion of a portion of a molded game ball section;

FIG. 7B is a side view of a portion of a portion of a molded game ball section;

FIG. 8 is a side view of a portion of a portion of a molded game ball section;

FIG. 9 is a perspective view of multiple molded game ball sections;

FIG. 10 is a perspective view of a complete molded game ball;

FIG. 11 is a schematic view of the method of making a game ball; and

FIG. 12 is a schematic view of an alternative method of making a game ball.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The claimed subject matter is now described with reference to the drawings. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the claimed subject matter. It may be evident, however, that the claimed subject matter may be practiced with or without any combination of these specific details, without departing from the spirit and scope of this invention and the claims.
Referring to FIG. 1 through FIG. 5, an embodiment of a male mold 100 utilized to manufacture the game ball is illustrated. The mold 100 comprises a mold base 110 and a male protrusion 120. In some embodiments the mold base 110 may have at least one cornered edge 160. The cornered edge 160 can be used for angular reference. The male protrusion 120 has the final desired shapes and contours for the final game ball. The male protrusion 120 has a plurality of pentagonal shapes 140 and a plurality of hexagonal shapes 130. Between each of the plurality of shapes is a border section 150. Surrounding the periphery edge of the male protrusion 120 are a plurality of molding connectors 124 and molding receivers 122. The molding connectors 124 are a plurality of indentations into the mold base 110. The molding receivers 122 are a plurality of protrusions from the mold base 110. There may be any number of molding connectors 124 and molding receivers 122 on the mold base 110. In the preferred embodiment, the number of molding connectors 124 is equal to the number of molding receivers 122. The molding connectors 124 and molding receivers 122 may be in any arrangement on the mold base 110. The molding receivers 122 and molding connectors 124 may alternate around the male protrusion 120. Alternatively, all molding receivers 122 may be on a side opposite from all molding connectors 124.
The mold 100 is used to form a polymer material into a partial section of a game ball. The segments of the ball are then combined together to form a complete game ball. The male mold 100 illustrated can be used to vacuum form material into the desired shape with the desired profile. It would be obvious to one skilled in the art that a female mold could be utilized as well. The female mold would have an internal profile identical to the profile of the male mold 100. The female mold could be used for vacuum forming a polymer into the desired shape or for compression molding or injection molding in connection with a male insert.
Referring to FIG. 6, a cross section of the molded game ball section 200 constructed with the mold 100 is illustrated. The game ball section 200 has an edge 220. The edge 220 has a plurality of connectors 224 formed by the molding connectors 124 and a plurality of receivers 222 formed by the molding receivers 122. The game ball section 200 has a plurality of molded pentagonal shapes 240 and molded hexagonal shapes 230. Between each of these plurality of molded shapes is a molded border section 250. The molded pentagonal shapes 240 and the molded hexagonal shapes 230 by the formed by the pentagonal shapes 140 and hexagonal shapes 130 of the mold 100 respectively. The molded border section is formed by the border section 150 of the mold 100.
Referring to FIG. 7A, a connector 224 is displayed. The connector 224 extends from the edge 220 of the molded game ball section 200. Referring to FIG. 7B, a receiver 222 is displayed. The receiver 222 extends into the edge 220 of the molded game ball section 200. The receiver 222 is a cavity that is complementary in shape to the connector 224. The molded game ball section 200 is molded so that two or more molded game ball sections 200 can be attached together at the respective edges 220. The connectors 224 of on edge 220 fit within the receivers 222 of the other edge 220. The connectors 224 and receivers 222 may be formed in any shape. In the embodiment illustrated the connectors 224 and receivers 222 are triangular in shape. In other embodiments the receivers 222 may be smaller at the edge 200 and open into a larger cavity, forming a lip which permits the connectors 224 to lock into place in the receivers 222.
Referring to FIG. 8, a close up view of the molded border section 250 is illustrated. The molded border section 250 comprises a bevel 252 depressing into the body of the molded ball section 200 and terminating into a groove 254. An identical bevel 252 extends upward on the opposite side of the groove 254. The molded border section 250 may be any size, shape, width, and depth. The bevel 252 may be any size, shape, and depth. The groove 254 may be any size, shape, and depth. FIG. 8 illustrates the preferred embodiment of the molded border section 250. In the preferred embodiment the molded border section 250 is twelve millimeters wide. The bevel 252 is 1.5 millimeters deep. The groove 254 is 0.4 millimeters wide and 0.3 millimeters deep. In the preferred embodiment the groove 254 is triangular in shape with a sixty degree angle of opening. In the preferred embodiment the groove 254 extends inward toward the center of the game ball, leaving 2.5 millimeters of thickness in the ball material from the tip of the groove 254 to the inside of the ball.
Referring to FIG. 9, the combination of multiple molded game ball sections 200 a, 200 b to form a completed game ball is illustrated. In this embodiment, each molded game ball section 200 a, 200 b is an identical hemisphere. The edge 220 of one molded game ball section 200 a is connected to the edge 220 of the other molded game ball section 200 b to form a complete spherical ball. In other embodiments the mold 100 is utilized to form partially spherical molded game ball sections 200. For instance, the mold 100 may be used to form four quarter-spheres which fit together to form a completed game ball. In addition, the mold 100 may be used to form eight eighth-spheres which can be fit together to form a completed game ball. The mold 100 may be used to form any sized portion of the spherical game ball which can be fit together with any number of other molded game ball sections 200 to form a complete spherical game ball.
Once the molded game ball sections 200 are fit together to form a completed game ball, the process may end there and the game ball may be used. However, referring to FIG. 10, an outer layer may be applied to the complete spherical game ball. The outer layer may be applied in larger sections or smaller sections. The outer layer may be used to provide a cosmetic appearance to the game ball. Additionally, the outer layer may be used to provide additional attributes to the game ball. As illustrated, the outer layer comprises a plurality of outer hexagonal shapes 330 and outer pentagonal shapes 340. Between each of the shapes is an outer border section 350.
The mold 100 may be used in any type of thermoforming process to manufacture the game ball. In addition, the mold 100 may be used in an injection molding, rotational molding, compression molding, blow molding, transfer molding, or any other type of elastomer or polymer molding process. Referring to FIG. 11 a method of making the game ball is illustrated. First a user selects a blank of material to be formed into a game ball section 400. The user then places the blank of material into the mold 402. The user then heats the blank to a desired temperature to ensure that the material is pliable 404. If the user is using compression molding then the user compresses the blank into the mold with hydraulic pressure 406. If the user is using a vacuum molding process the user creates a vacuum between the blank of material and the mold 408. Once the material has been molded into the proper shape, the material is cooled and the molded ball section is removed from the mold 410. If required, the user may remove excess material from the molded game ball section. The user combines multiple molded ball sections together to form a completed game ball 412. The user may use an adhesive to ensure that the connection between the edges remains secure. The user may also use an adhesive within the receivers 222 to ensure that the connectors 224 are permanently adhered within the receivers 222. The user may then apply an outer layer to the game ball 414.
Referring to FIG. 12, an alternative method of forming the game ball section through injection molding is illustrated. First, granular material is heated to a melting point 500. Then a cavity is created between a contoured female cavity and a male cavity 502. The melted material is injected into the cavity 504. The material is cooled and the molded game ball section is removed from the mold 506. If required the user may remove excess material from the molded game ball section. The user combines multiple molded ball sections together to form a completed game ball 508. The user may then apply an outer layer to the game ball 510.
In some embodiments, the molded game ball sections 200 may be adhered together at the edges with adhesive, ultrasonic welding, other means of attachment. The game ball may be formed from any type of material. In the preferred embodiment the molded game ball sections are formed of an elastomer, but other polymers and thermoplastics may be used. Ideally, the game ball section 200 is formed of polyurethane or thermoplastic polyurethane. The outer layer attached to the game ball may be made of any material, such as polyvinyl chloride, polyurethane, or any other polymer or elastomer.
The method of making the ball provides unforeseen benefits. The molding process can be used to create a soccer style game ball out of a minimum amount of material. Furthermore, the grooves molded into the surface of the game ball increases the strength of the game ball without increasing the thickness of the wall. In addition, the materials and grooves of the game ball create a rebounding and attribute in the game ball consistent with a standard soccer ball. In addition, the resulting game ball can be utilized without a bladder, allowing the ball to maintain a consistent internal pressure.
What has been described above includes examples of the claimed subject matter. It is, of course, not possible to describe every conceivable combination of components or methodologies for purposes of describing the claimed subject matter, but one of ordinary skill in the art can recognize that many further combinations and permutations of such matter are possible. Accordingly, the claimed subject matter is intended to embrace all such alterations, modifications and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.
The foregoing method descriptions and the process flow diagrams are provided merely as illustrative examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be appreciated by one of skill in the art the order of steps in the foregoing embodiments may be performed in any order. Words such as “thereafter,” “then,” “next,” etc. are not intended to limit the order of the steps; these words are simply used to guide the reader through the description of the methods. Further, any reference to claim elements in the singular, for example, using the articles “a,” “an” or “the” is not to be construed as limiting the element to the singular.

Claims

1. A method of making a game ball comprising

a. Selecting a blank of material;

b. Heating said blank of material;

c. Putting said blank of material into a mold

i. Said mold having a contoured face;

ii. Said contoured face comprising a plurality of hexagonal shapes, a plurality of pentagonal shapes, and a plurality of border sections, each of said border sections disposed between two of said shapes

1. Wherein said hexagonal shapes and said pentagonal shapes are situated in a predetermined pattern;

2. Wherein said border sections comprises a first bevel area, a second bevel area, and a groove disposed between said first bevel area and said second bevel area;

d. Deforming said blank of material;

e. Transferring said shape of said contoured face into said deformed blank of material;

f. Forming said deformed material into a molded game ball section

i. Creating a plurality of pentagonal shapes in the outer surface of said molded game ball section with said contoured face of said mold;

ii. Creating a plurality of hexagonal shapes in the outer surface of said molded game ball section with said contoured face of said mold;

iii. Creating a plurality of border sections disposed between two shapes in the outer surface of said molded game ball section with said contoured face of said mold;

iv. Creating a pair of bevel sections within each of said border sections in the outer surface of said molded game ball section with said contoured face of said mold;

v. Creating a groove disposed between each of said pair of bevel sections in the outer surface of said molded game ball section with said contoured face of said mold;

g. Cooling said molded game ball section;

h. Removing said molded game ball section from said mold;

i. Combining said molded game ball section with one or more other molded game ball sections to form a spherical game ball.

2. The method as in claim 1 further comprising

a. Ensuring each of said plurality of border sections molded into the outer surface of said molded game ball section is substantially twelve millimeters wide;

b. Ensuring each of said pair of bevels in said plurality of border sections molded into the outer surface of said molded game ball section is substantially 1.5 millimeters deep into the surface of said molded game ball section;

c. Ensuring each of said grooves in said plurality of border sections molded into the outer surface of said molded game ball section has a substantially triangular cross-sectional shape with an angle of sixty degrees, is substantially 0.4 millimeters wide at the surface of said molded game ball section, and is substantially 0.3 millimeters deep into the surface of said molded game ball section;

d. Ensuring that the thickness of the molded game ball section is substantially 2.5 millimeters from the inside edge of said molded game ball section to the outer edge of each of said plurality of grooves.

3. The method as in claim 1 further comprising

a. Creating a vacuum between said contoured face of said mold and said deformed blank of material.

4. The method as in claim 1 further comprising

a. Applying hydraulic pressure to said deformed blank of material to compress said deformed blank of material into said mold.

5. The method as in claim 1 further comprising

a. Applying an adhesive to the edge of said molded game ball section prior to adjoining said molded game ball sections.

6. The method as in claim 1 further comprising

a. Applying an adhesive to the outer surface of said spherical game ball;

b. Applying an outer layer of material to said outer surface of said spherical game ball.

7. The method as in claim 1 further comprising

a. Creating one or more connectors extending from the edge of said molded game ball section with said mold;

b. Creating one or more receivers extending into the edge of said molded game ball section with said mold;

c. Wherein said connectors of one molded game ball section are complementary to said receivers of a second game ball section;

d. Wherein said connectors of one molded game ball section are disposed within said receivers of a second game ball section when said molded game ball sections are combined together.

8. The method as in claim 3 further comprising

a. Applying an adhesive to the outer surface of said spherical game ball;

9. The method as in claim 8 further comprising

10. The method as in claim 9 further comprising

11. The method as in claim 4 further comprising

a. Applying an adhesive to the outer surface of said spherical game ball;

12. The method as in claim 11 further comprising

13. The method as in claim 12 further comprising

14. A method of making a game ball comprising

a. Heating a predetermined amount of particulate polymer material to a melting point;

b. Creating a cavity between a contoured female mold and a male mold

i. Said female mold having a contoured face;

c. Injecting a predetermined amount of said melted polymer into said cavity;

d. Forming said melted polymer into a molded game ball section

i. Creating a plurality of pentagonal shapes in the outer surface of said molded game ball section with said contoured face of said female mold;

ii. Creating a plurality of hexagonal shapes in the outer surface of said molded game ball section with said contoured face of said female mold;

iii. Creating a plurality of border sections disposed between two shapes in the outer surface of said molded game ball section with said contoured face of said female mold;

iv. Creating a pair of bevel sections within each of said border sections in the outer surface of said molded game ball section with said contoured face of said female mold;

v. Creating a groove disposed between each of said pair of bevel sections in the outer surface of said molded game ball section with said contoured face of said female mold;

e. Cooling said molded game ball section;

f. Removing said male mold from said female mold;

g. Removing said molded game ball section from said female mold;

h. Combining said molded game ball section with one or more other molded game ball sections to form a spherical game ball.

15. The method as in claim 14 further comprising

16. The method as in claim 14 further comprising

17. The method as in claim 14 further comprising

a. Applying an adhesive to the outer surface of said spherical game ball;

18. The method as in claim 14 further comprising

19. The method as in claim 18 further comprising

a. Applying an adhesive to the outer surface of said spherical game ball;

20. The method as in claim 20 further comprising