US20060148601A1

US20060148601A1 - Sportsball

Info

Publication number: US20060148601A1
Application number: US11/027,996
Authority: US
Inventors: Tsung Ou
Original assignee: Individual
Current assignee: Individual
Priority date: 2004-12-31
Filing date: 2004-12-31
Publication date: 2006-07-06

Abstract

A sportsball includes a ball cover and a rubber made inflatable bladder. The ball cover includes a plurality of cover panels, wherein each of the cover panels includes an outer layer and a cushion layer made of foaming material and integrally adhered with an outer surface of the inflatable bladder in an overlapped manner to cover the inflatable bladder to form the sportsball and the cushion layers and the inflatable bladder form an integral cushion for the sportsball.

Description

BACKGROUND OF THE PRESENT INVENTION

1. Field of Invention
The present invention relates to a ball, and more particularly to a sportsball which has a cushioned ball cover attached to an inflatable bladder to enhance the cushion effect of the sportsball by integrating the cushion layer of the ball cover with the rubber made inflatable bladder.
2. Description of Related Arts
Referring to FIG. 1A of the drawings, a conventional sportsball, such as a basketball, generally comprises a ball cover 10P′ and an inflatable bladder 20P′. For a basketball, the inflatable bladder 20P′ is a carcass having a plurality of channels 21P′ protruded thereon and the ball cover 10P′ comprises a plurality of cover panels 11P′, wherein the ball cover 10P′ is attached on the carcass 20P′ and the cover panels 11P′ are aligned between the channels 21P′. The ball cover 10P′ is made of genuine leather or synthetic leather materials, such as polyurethane (PU) or polyvinyl chloride (PVC), attached on the inflatable bladder 20P′. In order to assist the adhesion capability between the ball cover 10P′ and the rubber made inflatable bladder 20P′, the ball cover 10P′ further provides an inner lining 13P′ affixed on a bottom surface for adhering on the inflatable bladder 20P′ so as to attach the ball cover 10P on the inflatable bladder 20P′. In other words, the inner lining 13P′ is attached between the ball cover 10P′ (i.e. the cover panels 11P′) and the inflatable bladder 20P′ (the carcass) he outer layer 11P′.
Referring to FIG. 1B of the drawings, another kind of sportsball is illustrated, which comprises an inflatable bladder 20P and a ball cover 10P which comprises a plurality of cover panels attached on the inflatable bladder 20P at the corresponding channels 21P when the sportsball ball is a basketball, wherein each of the cover panel comprises an outer layer 11P, an intermediate cushion layer 12P, and an inner lining 13P. The inflatable bladder 20P is usually a spherical and elastic rubber-made membrane having a valve stem affixed thereon. The intermediate cushion layer 12P is included in this sportsball for providing a cushion effect for the ball cover 10P. FIG. 1C illustrates an alternative mode of the above sportsball as shown in FIG. 1B, wherein each cover panel of the ball cover 10P also provides with an inner lining 13P while two side edges of the channels 21P are inclined and arranged to fittedly adhere with the outer layer such that the ball cover 10P is slightly protruded with respect to the channels 21P in order to enhance the cushion effect of the ball cover 10P.
Practically, conventional adhesive resin would not be applied between the cushion layer 12P such as PU foam and the rubber material of the inflatable bladder 20P (carcass) because the adhesive resin would chemically react with the PU foaming material and the rubber material to form a certain amount of residual substance that deteriorates (sometimes severely) the adhesive performance of the resin. As a result, the cover panels 11P and the rubber inflatable bladder 20P fail to permanently and securely adhere together and thus adversely affect the life span and the performance of the sportsball.
Although the inner lining layer 13P substantially assists the ball cover 10P to attach on the inflatable bladder 20P, a major drawback comes with such inner lining layer 13P that its fiber nature affects the elasticity of the ball cover 10P. In addition, even though the rubber material of the inflatable bladder 20P is also an elastic material having cushion effect, the inner lining layer 13P substantially separates the inflatable bladder 20P with the cushion layer 12P that eliminates such elastic effect of the rubber made inflatable bladder 20P. As a result, the only portion that substantially provides the cushion effect for the entire sportsball is merely limited to the cushion layer 12P of the ball cover 10P. Therefore, the conventional sportsball becomes less appealing in terms of player's comfort and controllability of the sportsball.
Subsequently, in order to resolve this “by-product” of reducing elasticity and player's comfort of the additional inner lining layer 13P, those skilled in the art have utilized a thicker outer layer 11P or thicker cushion layer 12P, for compensating the loss of elasticity as a result of the inner lining layer 13P. This solves some of the problems regarding the performance of the sportsball and restores the comfort, yet thicker outer layer 11P or cushion layer 12P is more expensive than ordinary ball cover 10P and the result is that the overall manufacturing cost and the ultimate selling price of such a sportsball are inevitably increased. Most importantly, thicker outer or cushion layer 11P, 12P or even the inner lining layer 13P itself increases the overall thickness of the entire ball cover 10P. As a result, the sportsball may not comply with the relevant professional ball games regulations.

SUMMARY OF THE PRESENT INVENTION

A main object of the present invention is to provide a sportsball with improved cushion effect and a manufacturing method thereof, wherein a cushioned outer cover attached to an inflatable bladder to enhance the cushion effect of the sportsball by integrating the cushion layer of the ball cover with the rubber made inflatable bladder.
Another object of the present invention is to provide a sportsball having a better adhesive effect between the cushioned outer cover and the inflatable bladder so as to achieve better performance of the sportsball and reduce the manufacturing cost thereof.
Another object of the present invention is to provide a sportsball and the manufacturing method thereof, wherein a treatment agent is applied between the cushioned outer cover and the inflatable bladder for eliminating unwanted chemicals formed when adhering the ball cover with the inflatable bladder through conventional adhesive agent, so that the sportsball of the present invention provides enhanced adhesive strength and quality between the ball cover and the inflatable bladder, as well as between the outer cover and the cushion layer where the outer cover is made of synthetic material such as rubber.
Another object of the present invention is to provide a sportsball with improved cushion and a manufacturing method thereof that eliminates the need for introducing additional elements, such as a fabric layer or lining layer, to the sportsball for compensating the unstable adhesive quality occurred in conventional arts.
Another object of the present invention is to provide a sportsball with enhanced cushion effect without increasing the overall size of the sportsball.
Accordingly, in order to accomplish the above objects, the present invention provides a sportsball which comprises:
an inflatable bladder having an air inlet valve stem; and
a ball cover which comprises a plurality of cover panels covering the inflatable bladder to form the sportsball, wherein each of the cover panels comprises an outer layer and a cushion layer integrally adhered with the outer layer in an overlapped manner, wherein the cushion layers and the inflatable bladder integrally form an integral cushion for the sportsball.
When the cushion layers are made of foaming material and the inflatable bladder is made of rubber, a treatment agent is applied between attachment sides of the cushion layers of the cover panels and an outer surface of the inflatable bladder before adhering attachment sides of the cushion layers to said outer surface of the inflatable bladder.
Moreover, the present invention also provides a method of manufacturing a sportsball, comprising the steps of:
(1) providing a plurality of outer layers, each of the outer layers has a predetermined size and shape;
(2) providing a plurality of cushion layers, wherein each of the cushion layers is cut into a predetermined size and shape corresponding to the outer layers;
(3) providing an inflatable bladder having a plurality of channels formed thereon to define a plurality of attachment grooves between each two channels;
(4) attaching the outer layers with the cushion layers respectively to form a plurality of cover panels;
(5) applying a treatment agent on an attachment side of each of the cushion layers of the cover panels;
(6) applying an adhering agent on an outer surface of the inflatable bladder at the attachment grooves; and
(7) attaching each of the cover panels to the respective attachment grooves, wherein the treatment agent is chemically reacted with the adhering agent such that the cover panels are integrally bonded with the foaming inflatable bladder in an overlapped manner to form an integral cushion for the sportsball.
These and other objectives, features, and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings, and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a conventional sportsball, illustrating that the ball cover is made up by an outer layer and an inner lining.
FIG. 1B is a conventional sportsball, illustrating that the ball cover is made up by an outer layer, a cushion layer, and an inner lining.
FIG. 1C is a conventional sportsball, illustrating that the ball cover is made by an outer layer, a cushion layer, and an inner lining, wherein the three layers form a pop up structure.
FIG. 2 is a perspective view of a sportsball according to a preferred embodiment of the present invention.
FIG. 3 is a sectional view of the sportsball according to the above preferred embodiment of the present invention.
FIG. 4 is a schematic diagram of a method of manufacturing a sportsball according to the above preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 2 to FIG. 4 of the drawings, a perspective view of a sportsball, such as a basketball, according to a preferred embodiment of the present invention is illustrated, in which the sportsball comprises a ball cover 10 and an inflatable bladder 20.
The ball cover 10, having a stem hole 12 formed thereon, comprises a plurality of cover panels 11, wherein each of the cover panels 11 comprises an outer layer 111 and a cushion layer 112 which is made of foaming material and integrally adhered with the outer layer 111 in an overlapped manner.
Each of the cover panels 11 is formed by the outer layer 111 having a predetermined shape, such as that forming an elongated elliptical shape. On the other hand, each of the cushion layers 112 has the corresponding shape as that of the respective outer layer 111 so as to integrally and overlappedly attach underneath that respective outer layer 111 to form a particular cover panel 11.
According to the preferred embodiment, the outer layer 111 of each of the cover panels 11 is made of leather, synthetic leather such as polyvinyl chloride (PVC) or polyurethane (PU), or rubber, which are capable of sustaining a substantial degree of impact while retaining sound flexibility for sophisticated ball control by a player. Typically, each of the outer layers 111 provides a plurality of protruding pebbles distributed all over an outer surface thereof, so as to facilitate the secure gripping and holding of the sportsball by the player.
The inflatable bladder 20 has a valve stem 21 aligned with the stem hole 12, wherein the ball cover 10 is attached on an outer surface 111 of the inflatable bladder 20. The inflatable bladder 20, which is generally made of rubber or the like, has a predetermined shape. The valve stem 21 of the inflatable bladder 20 is aligned and attached with the stem hole 12 of the ball cover 10, wherein a user is able to inflate the sportsball via the valve stem 21 and the stem hole 12. When the inflatable bladder 20 is inflated via the valve stem 21, it is popped up to expand against the ball cover 10 to form an inflated sportsball.
Referring to FIG. 2 to FIG. 3 of the drawings, according to the preferred embodiment, the inflatable bladder 20 has a plurality of channels 22 protruded thereon to define a plurality of attachment grooves 221 formed between each two channels 22 to form an inflatable bladder for basketball, wherein each of the cover panels 11 is fittedly attached on the respective attachment groove 221.
In order to enhance the attachment between the cushion layer 112 and the inflatable bladder 20 and the cushioning effect of the sportsball, two inclined side edges 1121 of each of the cushion layers 112 can be cut inclinedly and also attached to the outer surface within the respective attachment groove 221 of the inflatable bladder 20 so that each of the cover panels 11 is slightly protruded along the channels 22 so as to enhance an overall attachment strength as well as the cushioning effect of the sportsball.
Thus, where the outer layer 111 is made of leather, synthetic leather or rubber, each of the cover panels 11 further comprises an adhering agent 114 applied between its outer layer 111 and cushion layer 112 to permanently adhere the outer layer 111 with the cushion layer 112 to form the integral cover panel 11 which has an ability to sustain substantial impact while retaining optimal flexibility. Moreover, the adhering agent 14 is also used to attach the cushion layer 112 to an outer surface of the inflatable bladder 20 so as to form the sportsball of the present invention.
It is worth to mention that common adhering agent 114, such as adhesive resin which has a predetermined adhesive ability, would chemically react the rubber and foaming material and produce a certain amount of unwanted chemical substances that, in the ordinary course of event, may deteriorate the adhesion quality between the cushion layer 112 made of foaming material and the rubber made inflatable bladder 20 and the cushion layer 112 and the outer layer 111 when it is made of rubber. Accordingly, each of the cover panels 11 further comprises a treatment agent 115 which is applied between the cushion layer 112 and the inflatable bladder 20 (as well as between the cushion layer 112 and the outer layer 111 when it is made of rubber), wherein the treatment agent 115 should have a chemical property capable of preventing the formation of the above mentioned unwanted chemical substances.
According to the preferred embodiment of the present invention, the treatment agent 115 comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK. The corresponding percentage of each of these elements is:
60%-70% of chloroprene rubber—60%-70%;
34%-22% of solvent refined heavy naphtha; and
1%-2% of MEK (Methylethyl Ketone).
Moreover, the chemical features and the environmental impact of the treatment agent 115 are briefly outlined as follows:
Storage temperature—room temperature
Handling/storage—the treatment agent is to be stored in dry, cool area
Appearance—Light yellow liquid
Boiling point—approximately 95° C.
Odor—Distinct odor
Specific gravity—0.800+/−0.005 (/15+/−1° C.)
Solubility in Water: Insoluble
Stability—stable at room temperature
Condition to avoid—avoid contact to heat, spark, flames or other sources of ignition
Thermal decomposition—carbon oxide and other unknown organic compounds
In view of above, it is appreciated that the sportsball of the present invention does not utilize any inner lining for the adhesion between the inflatable bladder 20 and the cushion layer 112 and/or between the cushion layer 112 and the outer layer 11 when it is made of rubber. To eliminate of the inner lining and to enable the cushion layer 112 directly attached on the inflatable bladder 20 not only can reduce the cost of the lining material and the manufacturing step of securely attaching the lining layer to the cushion layer, but also can enhance the overall cushion effect of the sportsball that the elasticity of the inflatable bladder 20, generally made of rubber, also provides cushion effect in addition to the foaming material of the cushion layer 112. That is the cushion layer 112 and the inflatable bladder 20 forms an integral cushion layer. In other words, the inflatable bladder 20 also functions as a part of the cushion layer. The sportsball with better cushion effect according to the present invention is more easily and comfortable to grip and to play. Also, to reduce the manufacturing cost and selling price, the thickness of the cushion layer 112 can be reduce while a cushion effect as good as the conventional sportsball may still be provided.
Referring to FIG. 4 of the drawings, a method of manufacturing the above disclosed sportsball comprising the steps of:
(1) providing the plurality of outer layers 111, each of the outer layers 111 has a predetermined size and shape;
(2) providing the plurality of cushion layers 112, wherein each of the cushion layers 112 is cut into a predetermined size and shape corresponding to that of the outer layer 111;
(3) providing the inflatable bladder 20 having the plurality of channels 22 formed thereon to define the plurality of attachment grooves 221 between each two channels 22;
(4) attaching the outer layers 111 with the cushion layers 112 respectively to form the plurality of cover panels 11;
(5) applying the treatment agent 115 between the attachment side of each of the cushion layers of the cover panels and an outer surface of the inflatable bladder;
(6) applying an adhering agent 114 on the outer surface of the inflatable bladder at the attachment grooves; and
(7) attaching each of the cover panels 11 to the respective attachment grooves 221, wherein the treatment agent 115 is chemically reacted with the adhering agent 114 such that the cover panels 11 are integrally bonded with the inflatable bladder 20 in an overlapped manner to form an integral cushion for the sportsball.
In addition, the step (4) further comprises the steps of:
(4.1) applying resin as an adhering agent 114 on each of the cushion layers 112 to integrally bind the outer layers 111 with the cushion layers 112 in an overlapped manner respectively; and
(4.2) applying a treatment agent 115 on each of the outer layers 111 when the outer layer 111 is made of rubber.
In order to enhance the attachment between the cushion layer 112 and the inflatable bladder 20 and the cushioning effect, as mentioned above, each of the cushion layers 112 has two inclined side edges 1121 attached on the outer surface of the inflatable bladder 20 within the respective attachment groove 221 so as to enhance an overall attachment strength of the sportsball as well as the cushioning effect thereof.
One skilled in the art will understand that the embodiment of the present invention as shown in the drawings and described above is exemplary only and not intended to be limiting.
It will thus be seen that the objects of the present invention have been fully and effectively accomplished. It embodiments have been shown and described for the purposes of illustrating the functional and structural principles of the present invention and is subject to change without departure from such principles. Therefore, this invention includes all modifications encompassed within the spirit and scope of the following claims.

Claims

1. A sportsball, comprising:

an inflatable bladder having an air inlet valve stem; and

a ball cover which comprises a plurality of cover panels each of which comprises an outer layer and a cushion layer integrally adhered with said outer layer in an overlapped manner, wherein attachment sides of said cushion layers of said cover panels are attached on an outer surface of said inflatable bladder to cover said inflatable bladder to form said sportsball and each of said cover panels said cushion layers and said inflatable bladder form an integral cushion for said sportsball.

2. The sportsball, as recited in claim 1, wherein said inflatable bladder is made of rubber and said cushion layers are made of foaming material, wherein a treatment agent is applied between said attachment sides of said cushion layers of said cover panels and said outer surface of said inflatable bladder before adhering said attachment sides of said cushion layers to said outer surface of said inflatable bladder.

3. The sportsball, as recited in claim 1, wherein said outer layers are made of rubber and said cushion layers of said cover panels are made of foaming material, wherein a treatment agent is applied between inner sides of said cushion layers and outer surfaces of said outer layers before adhering said inner sides of said cushion layers to said outer surfaces of said outer layers respectively.

4. The sportsball, as recited in claim 2, wherein said outer layers are made of rubber and said cushion layers of said cover panels are made of foaming material, wherein said treatment agent is applied between inner sides of said cushion layers and outer surfaces of said outer layers before adhering said inner sides of said cushion layers to said outer surfaces of said outer layers respectively.

5. The sportsball, as recited in claim 1, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

6. The sportsball, as recited in claim 2, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

7. The sportsball, as recited in claim 3, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

8. The sportsball, as recited in claim 4, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

9. The sportsball, as recited in claim 2, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

10. The sportsball, as recited in claim 4, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

11. The sportsball, as recited in claim 6, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

12. The sportsball, as recited in claim 8, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

13. The sportsball, as recited in claim 2, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

14. The sportsball, as recited in claim 4, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

15. The sportsball, as recited in claim 6, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

16. The sportsball, as recited in claim 8, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

17. A method of manufacturing a sportsball, comprising the steps of:

(a) providing an inflatable bladder having an air inlet valve stem thereon;

(b) providing a plurality of outer layers, each of said outer layers has a predetermined size and shape;

(c) providing a plurality of cushion layers, wherein each of said cushion layers is cut into a predetermined size and shape corresponding to that of said respective outer layer;

(d) attaching each of said outer layers with said cushion layers respectively to form said cover panels;

(e) applying an adhering agent on an attachment side of each of said cushion layers of said cover panels; and

(f) attaching attachment sides of said cushion layers of said cover panels on an outer surface of said inflatable bladder to cover said inflatable bladder to form said sportsball and each of said cover panels said cushion layers and said inflatable bladder form an integral cushion for said sportsball.

18. The method, as recited in claim 17, wherein said cushion layers which are made of foaming material are adhered on said outer surface of said inflatable bladder which is made of rubber, wherein the method further comprises a step of applying a treatment agent between the attachments sides of said cushion layers of said cover panels and said outer surface of said inflatable bladder to ensure integrally attachment of said cushion layers with said inflatable bladder in an overlapped manner to form said sportsball.

19. The method, as recited in claim 17, wherein said outer layers are made of rubber and said cushion layers of said cover panels are made of foaming material, wherein the method further comprises a step of applying a treatment agent between inner sides of said cushion layers and outer surfaces of said outer layers before adhering said inner sides of said cushion layers to said outer surfaces of said outer layers respectively.

20. The method, as recited in claim 18, wherein said outer layers are made of rubber and said cushion layers of said cover panels are made of foaming material, wherein the method further comprises a step of applying a treatment agent between inner sides of said cushion layers and outer surfaces of said outer layers before adhering said inner sides of said cushion layers to said outer surfaces of said outer layers respectively.

21. The method, as recited in claim 17, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

22. The method, as recited in claim 18, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

23. The method, as recited in claim 19, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

24. The method, as recited in claim 20, wherein said inflatable bladder has a plurality of channels protruded thereon to define a plurality of attachment grooves formed between each two of said channels, wherein said cover panels are fittedly attached on said attachment grooves respectively.

25. The method, as recited in claim 18, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

26. The method, as recited in claim 20, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

27. The method, as recited in claim 22, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

28. The method, as recited in claim 24, wherein said treatment agent comprises a predetermined amount of chloroprene rubber, a predetermined amount of solvent refined heavy naphtha, and a predetermined amount of MEK (Methylethyl Ketone).

29. The method, as recited in claim 18, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

30. The method, as recited in claim 20, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

31. The method, as recited in claim 22, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).

32. The method, as recited in claim 24, wherein said treatment agent comprises a 60%-70% of chloroprene rubber, a 34%-22% of solvent refined heavy naphtha and 1%-2% of MEK (Methylethyl Ketone).