CLOSING FINAL PANELS OF MACHINE SEWN SPORTS BALLS

Abstract

In a sports ball, such as a soccer ball, which comprises a plurality of shaped panels which are joined together by stitching to form an enclosed volume housing a bladder for inflation, several contiguous seams are left unstitched but are instead joined together adhesively by means of an underlying fabric patch. The contiguous seams are preferably provided with curved edges and markings to simulate stitching. The fabric patch is adhesively attached to the bladder (which preferably includes an over winding) and to the panels having the contiguous seams.

Claims

1. An object for sports play comprising: a plurality of exterior, stitched together panels sewn at their edges, configured to form a closed volume and forming, by said stitching, raised interior edges at the edges of said panels; an inflatable bladder occupying said closed volume; a subset of said plurality of exterior panels forming an adjacent set of said panels having edges lying at a closure for said ball; and a patch lying beneath and between said adjacent ones of said closure forming panels and adhesively affixed thereto.

2. The object of claim 1 in which said patch is further adhesively affixed to at least one of said panels

3. The object of claim 1 in which said adjacent set of said panels have curved edges, whereby said edges more closely resemble said stitched together panels.

4. The object of claim 3 further including markings along said curved edges which simulate stitching;

5. The object of claim 3 in which said curved edges are joined with adhesive.

6. The object for sports play of claim 1 which is in the shape of a soccer ball.

7. The object of claim 1 in which bladder is covered in an exterior winding for strength.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with the further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:

[0025] FIG. 1 is an isometric view illustrating three adjacently positioned geometrically shaped panels such of those that are employed in the edges manufacture of soccer balls;

[0026] FIG. 2 is a view similar to FIG. 1 which more particularly illustrates the presence of curved edges;

[0027] FIG. 3 illustrates the placement of pentagonal and hexagonal panels, in which a closure opening consists of four panel edges;

[0028] FIG. 4 is a view similar to FIG. 3 in which only two panel edges remain to be permanently joined;

[0029] FIG. 5 illustrates the placement of adhesive material on the edges of three panels in a view in which the outer layer of the sports ball is shown inside out;

[0030] FIG. 6 is a view similar to FIG. 5 more particularly illustrating initial stages of the placement of a closure strip in accordance with the present invention;

[0031] FIG. 7 illustrates the use of fabric strips in accordance with the present invention in conjunction with panel seams that are sewn;

[0032] FIG. 8 illustrates the relationship between the structure shown in FIG. 7 and the interior bladder which is also found to be wound with thread material as shown;

[0033] FIG. 9 is an exploded view of facing panel edges with their ends abutting and more particularly intending to illustrate seams having conventional stitching;

[0034] FIG. 10 illustrates the traditional method of joining the final panel openings using an adhesive in which adhesive material ends up being dripped on thread material which has been wound on the bladder;

[0035] FIG. 11 is related to FIG. 3 and illustrates placement of a fabric strip covering four panel edges that surround the area left for bladder insertion;

[0036] FIG. 12 is similar to FIG. 11 but also showing the use of additional fabric cross strips for extra strength;

[0037] FIG. 13 is similar to FIG. 4 illustrating a fabric patch applied across two seams;

[0038] FIG. 14 is similar to FIG. 13 also showing the use of supplementary fabric cross strips;

[0039] FIG. 15 is an exterior view of a soccer ball in which only two seams are joined by the closure method shown herein; and

[0040] FIG. 16 is a view similar to FIG. 15 in which four seams are joined by the closure method shown herein.

[0041] FIG. 17 is a more detailed view of FIG. 10 which shows a completed seam in greater detail.

DETAILED DESCRIPTION

[0042] In preferred embodiments of the present invention, all of the sports ball panels are sewn by machine and the sewing side of the ball is turned outside-in.

[0043] Firstly, all of the ball panels are sewn by a machine sewing method and the sewing side of the ball is turned outside in. In preferred embodiments of the present invention and, in particular for the manufacture of soccer balls, typically either two or four adjacent seams are left unsewn. It is through this area that a bladder is ultimately inserted. The present invention also provides these seams with shape edges so that the completed product is rendered more capable of being treated as if all of the panel edges appear to be sewn. These shape edges are described herein as being either curved, shaped, beveled or rounded. Once sewing of the whole ball is completed, these pre-shaped panels are left without sewing and their edges are applied with adhesive. After adhesive is dried then a fabric strip is placed underneath the unsewn panel edges which are already coated with bonding adhesive. A fabric strip is placed underneath the unsewn panel edges and serves to hold abutting edges together. Once the fabric strip is positioned to hold the panels edges from underneath, the edges are joined together and placed in a heating mold. With the application of heat in the mold, adhesive on the panel edges activates and bonds the intended panels together. Similarly, adhesive on the fabric strip underneath the panels bonds with the backing fabric of the ball's exterior panels thus providing a strong dual bonding of the panels. This bond is stronger than the traditional bonding method of only bonding the confronting edges together. The size and shape of the supporting fabric strip is designed to conform to the shape and size of exterior ball panel shapes.

[0044] In one aspect of the present invention (one with an opening provided by two adjacent seams), an opening is provided by two edges of one pentagonal panel which faces one each edge of two adjacent hexagonal panels. This varies from one ball to another depending on the shape of the ball. Different types and shapes of fabric strip are used to close and strengthen the final openings of a ball. The most important aspect of the fabric strip is that it spans and adhesively connects adjacent panels along the panels that form an opening for insertion of an inflatable bladder. The last closing panels edges are turned on their edges which are preferably beveled and glued to bond with each other.

[0045] In the manufacture of soccer balls, the panel edges are turned downward approximately 2 to 3 mm in the same way as they would be turned when sewing two panels together from its edge depending on the thickness of the material which can vary in practice. The panel edges then faces down substantially vertically and rest on the supporting fabric strip provided underneath for support and strength and for keeping glued edges together and preventing slippage and sliding when the ball is fully inflated and undergoes enormous kicking and shooting during play. Ball panel edges are turned in so as to resemble sewn edges which sit correctly and fit perfectly with other sewn panels.

[0046] Various aspects of the present invention are illustrated in the accompanying drawings. For example, FIG. 1 illustrates a set of typical panels 101-103 that typically comprise a sports ball. In particular, there is shown pentagonal panel 101 along with hexagonal panels 102 and 103. In a typical sports ball manufactured in accordance with the present invention hexagonal panels 102 and 103 are joined by stitching, preferably machine stitching. It is thus seen that pentagonal panel 101 shares to adjacent edges or seams with the other two panels. It is these other two seams that are relevant to the sports balls described herein.

[0047] FIG. 2 is similar to FIG. 1 except that it were clearly illustrates curved edges 110. These edges are joined adhesively in conjunction with the use of an underlying fabric strip that serves to more securely provide closure of the ball after insertion of the bladder through a temporary opening provided by curved or beveled edges 110.

[0048] As indicated above, the opening provided for sports ball closure may include any desirable number of contiguous or adjacent seams. However, in the case of a soccer ball, for example, it is convenient to use either a four-seam opening as shown in FIG. 3 or a two-seam opening as seen in FIG. 4. In the case of a four-seam opening as shown in FIG. 3 it is seen that hexagonal panel 102 having edges 102A and 102B are ultimately joined with edges 104A (on hexagonal patch 104) and 101A on pentagonal panel 101, respectively, as shown. Similar adjacency is provided between edge 103A on hexagonal patch 103 and edge 101B panel 101. A similar relationship exists for hexagonal panels 103 and 105 along edges 105A and 103B respectively.

[0049] FIGS. 5 and 6 illustrate an exemplary soccer ball made in accordance with the present invention. In particular, these two drawings indicate such a ball being inverted with the sewn seams present on the exterior of the two structures. In particular, these two drawings illustrate the presence of machine sewn seams 200. Additionally, final seams forming opening 140 are present using curved or beveled edges 110. For continuity purposes relative to FIG. 1-4, similarly positioned pentagonal panel 101 is shown in its relationship to hexagonal panels 102 and 103. More particularly, FIG. 6 indicates the presence of fabric strip 150 as it is being applied across opening 140. Importantly for one aspect of the present invention edges 110 are curved or beveled so that they may be made to work closely resemble a sewn seam, as described above.

[0050] FIG. 7 illustrates the relationship between two hexagonal panels 102 and 103 with respect to fabric strip 150. More particularly, it is seen that the hexagonal panels are joined by conventional stitching 200, perfectly provided by machine. It is further noted that curved or beveled edges 110 are shown as also being part of panels 102 and 103 all of which overlie fabric 150. FIG. 8 is similar to FIG. 7 except that it includes pentagonal panel 101 and also shows the relationship with bladder 160 which possesses windings 165 for strength and protection of inflatable bladder 160. FIG. 8 is also relevant in that curved or beveled edges of pentagonal panel 101 are shown in their final position. It is noted that for purposes of illustration FIG. 8 is an exploded view.

[0051] FIG. 9 illustrates the relationship between fabric strip 150 and edge seam 110 just prior to its being adjacently disposed. FIG. 10 illustrates the traditional method of joining the final panel openings using adhesive 111 in which adhesive material ends up being dripped on thread windings 165 provided over bladder 160. This is undesirable.

[0052] As mentioned elsewhere herein, one of the features that is provided in the present invention is the capability to render the final closure of the present invention more capable of resembling and/or simulating a sewn seam. As described above, beveled edges 110 are joined adhesively in an edge-to-edge fashion and in this way already resemble a sewn seam. However, it is noted that panels herein that are joined adhesively at the closure or also preferably provided with markings 112 which mimic stitching 200 present on other portions of the sports ball.

[0053] FIG. 17 illustrates a close up view of FIG. 10 so as to show a closer view of panel junctions 110 at the closing seam. Reference numeral 110 is best describable as the part of panel closure seams that are externally visible. The visible curved or beveled edges referenced herein by reference numeral 110 are seen in greater detail in FIG. 17 which shows these edges as including two specific regions which are not easily visible in a completed ball: a face region 113 (also describable as being a curved head) and substantially flat floor region 114 which is directly attached to fabric strip 150 using adhesive.

[0054] FIGS. 11 through 14 illustrates the placing of fabric strip 150 over the seams which participate in the final closure opening. It is through this opening that bladder 160 is inserted before final closure. In FIGS. 11 and 12 there is provided an example of fabric strip 150 being disposed over four seams, while FIGS. 13 and 14 illustrates fabric strip 150 being disposed across only two seams. Is noted that the present invention is capable of employing any convenient number of seams and is not limited to either two or four. Seams.

[0055] It is noted that fabric strips 150 may also be provided with cross steps 155A and 155B as shown in FIG. 12 when fabric strip 150 is disposed over a four seam opening. In situations where fabric strip 150 is disposed opposite only two seams as seen in FIG. 14, fewer cross strips 155 are provided.

[0056] FIGS. 15 and 16 provide exterior views of soccer balls manufactured in accordance with the present invention. In particular, in these drawings reference numeral 200 refers to conventional machine sewn seams. In contrast, closing seams in accordance with the present invention are illustrated by reference numeral 110. In FIG. 15 two such closing seams are shown. In FIG. 16 there are four such seams shown.

[0057] The panels of sports balls in accordance with the present invention (especially soccer balls) typically include three layers: a fabric layer, which is totally distinct from fabric strip 150, a middle foam layer and an outer layer which is typically a layer of TPU (thermoplastic urethane) or PU (polyurethane). In accordance with the present invention, it is seen that the faces of beveled edges 110 are turned and rest on fabric strip 150. When fully shaped, the top layer, middle foam and backing fabric become parallel to the rest of the flat body surface and stand horizontal to the rest of its area and lays flat on supporting fabric strip 150.

[0058] It is noted that the present invention finds particular utility in the manufacture of machine sewn sports balls; nonetheless, the methods and structures of the present invention are not limited to sports balls that are sewn only by machine. While the illustrations shown herein are directed to the manufacture of a soccer ball, the methods and structures of the present invention are applicable to the production of other sports balls. The present invention is especially directed to the construction of sports balls formed from a plurality of particularly shape panels that are sewn together by machine. Collectively, the stitched together panels form an enclosed volume into which to an inflatable bladder is inserted. In preferred embodiments of the present invention, the bladder is also wound with thread, cord, or string so as to provide improved play characteristics. It is also noted that the strip fabric comprises any kind of strong woven fabric having singular or multiple layers. Any type of strong adhesive is used to bond the panels and the fabric strip.

[0059] All publications and patent applications mentioned in this specification are indicative of the level of skill of those skilled in the art to which this invention pertains. All publications and patent applications are herein incorporated by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated by reference.

[0060] Although the description above contains many specifics, these should not be construed as limiting the scope of the invention, but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus, the scope of this invention should be determined by the appended claims and their legal equivalents. Therefore, it will be appreciated that the scope of the present invention fully encompasses other embodiments which may become obvious to those skilled in the art, and that the scope of the present invention is accordingly to be limited by the appended claims, in which reference to an element in the singular is not intended to mean one and only one unless explicitly so stated, but rather one or more. All structural, chemical, and functional equivalents to the elements of the above-described preferred embodiment that are known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the present claims. Moreover, it is not necessary for a device or method to address each and every problem sought to be solved by the present invention, for it to be encompassed by the present claims. Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 USC 112, sixth paragraph, unless the element is expressly recited using the phrase means for.

[0061] While the invention has been described in detail herein in accordance with certain preferred embodiments thereof, many modifications and changes therein may be effected by those skilled in the art. Accordingly, it is intended by the appended claims to cover all such modifications and changes as fall within the spirit and scope of the invention.