BALL WITH INTERIOR REINFORCEMENT PATCHES

TECHNICAL FIELD

The present invention is generally directed to balls for sporting activities. More particularly, the present invention is directed to soccer balls and to volleyballs. Even more particularly, the present invention is directed to sports balls and their manufacturing processes. Even more particularly, the present invention is directed to improvements in the processes and structures employed in balls that are sewn by machine.

BACKGROUND OF THE INVENTION

Traditional hand sewn balls are produced by joining cut panels together by hand sewing by with thread which is thick and strong. Each stitch is pulled by hand by a skilled worker to make the stitch tighter and secure it from opening so as to withstand the pressure of an inflated inner bladder especially during striking and kicking the ball during play. The typical sports ball is produced using a latex rubber bladder without having any rewound thread around it to prevent its expansion during use. The panels are joined by hand sewing and, because of this, are strong enough to bear the stresses of an inflated inner bladder pressure.

During the hand sewing process, workers use small strands of threads to stitch panels together and they have to use many strands before a ball is completed. Each time a new strand is used, it must be secured properly with previous stitching which tends to produce knots. These strands are employed to prevent the stitching from unraveling during play. However, some workers leave it without properly securing it with a knot. As a result, ball stitching is opened up and bladder pressure inside the ball pushes the bladder outwards and thus making the ball not usable for play.

Another drawback is that, since the thread used in hand sewing is often thick and sometimes two strands of thread are tied together with each other and they form a thick knot of thread which sticks out inside the ball against the inflated bladder. This often causes a leak in the inflated bladder body.

There is also a problem with machine sewn balls that include a thread rewound bladder. Traditional machine sewn balls that are produced using a sewing machine to join the ball panels together do not produce balls that are strong enough to sustain inflated inner bladder pressure and therefore an inner bladder is provided with a rewound web of yarn or thread all around the bladder which prevents its outward expansion and the exertion of pressure on the machine sewn exterior cover. This helps to prevent the tearing of the stitching on the exterior cover during kicking or striking during play.

Balls with a rewound web of yarn or thread all around the bladder do not provide a lively feel during play. In this case the exterior machine sewn cover is provided with a thick foam to improve its softness and feel. Its softness and feel is limited to the thickness of the outer foam covering. Having an inner bladder with a web of yarn wound around it does not promote flexing and does not give a lively feel and response to the player when the ball is kicked or struck.

In another embodiment of sports balls a machine sewn ball may be provided with a simple bladder without having any interior rewind covering of a thread web over the bladder to control its expansion. However, this ball is not particularly strong because the inner inflated bladder pressure is applied directly on the machine sewn thread joints and thus the stitches are easily ripped and torn apart during play while striking or kicking. In such a structure, the interior bladder does not have any kind of covering over it to stop its expansion. Therefore most of the pressure produced by the inflated bladder is applied directly on the ball's exterior cover and the sewing. Due to this structure, during play or otherwise, there can often be an increase in the overall size of a ball which is not acceptable to ball regulatory authorities such as the FIFA (International Federation of Association Football) in case of soccer and the FIVB (Federation Internationale de Volleyball) in case of Volleyball or other regulatory authorities. In this case, the interior bladder does not having any kind of covering on it to stop its expansion.

In yet another sports ball embodiment which has undesirable limitations, one finds a machine sewn ball in which fabric patches are pasted to the bladder to prevent its expansion outward and to stop damage to the machine sewn stitches caused by inflated bladder pressure. This ball has same problem as the one having a rewound thread web around it. The fabric patches in this ball structure are pasted on the bladder; however, this does not permit the bladder to properly flex. Therefore, this does not provide a desired level of feel and responsiveness that is found in a ball having a bladder without any type of cover, whether a web of thread or fabric patches.

In addition, there are other drawbacks commonly found in sports ball manufacture. In particular, in all traditional balls whether hand sewn ball or machine sewn, water is able to penetrate inside the ball during play on wet ground and as a result the ball weight is increased and makes it heavier to play with. Accordingly, in this circumstance, water inside, if not properly dried after play, causes mold inside the ball thus completely damaging the ball. If one tries to seal the joint seams with some form of adhesive from the outside to stop water from seeping into the interior of ball, it is often the case that this adhesive comes off after a few games through wear and tear and contact with the ground. Another disadvantage of adhesive application is that it is difficult to apply an adhesive uniformly on the seams of the ball and to avoid damaging the cosmetic appearance of the ball during the sealing process. Another major problem with all of the hand sewn and machine sewn balls is that, when the thread joining the panels together is torn or when it unravels, it exposes the bladder due to the internal bladder pressure. This forms a gap between sewn panels and therefore ball is deformed and not usable for play. There is yet another big drawback for hand sewn balls is that if a thread is torn off or broken, there is can arise a big gap between panels which is formed due to internal bladder pressure. Particularly during “heading” (striking with the head) in the game of soccer, this can cause injury.

In view of the above there is a need to have a machine sewn sports ball having a stronger exterior cover comprising panel which are stitched together to form a spherical (or other) shape and stitching does not open or break due to internal inflated bladder pressure. From the above, it is therefore seen that there exists a need in the art to overcome the deficiencies and limitations described herein and above.

SUMMARY OF THE INVENTION

It should be appreciated that this Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to be used to limit the scope of the claimed subject matter.

The shortcomings of the prior art are overcome and additional advantages are provided through the use of patches disposed over the internal stitched seems of sporting balls such as soccer balls and volley balls. In view of the above there is a need to have a machine sewn ball having stronger exterior cover panels stitched together to form a desired shape and in which thread stitching does not open or break due to internal inflated bladder pressure.

More particularly, the present invention includes 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. The ball also includes an interior bladder which, when inflated, presses up against the panels and the stitching. Lastly, and most importantly, there is provided a plurality of patches adhered to adjacent ones of the panels, on their interior portions, and disposed over the stitching. Depending on the panels used to form an enclosed volume, the patches have shapes intended to cover the stitching.

Accordingly, it is an object of the present invention to protect the interior ball stitching from breaking due to internal inflated bladder air pressure.

It is also an object of the present invention to promote the production of soccer balls, volley balls and the like through the use of machine sewing, as opposed to hand sewing.

It is another object of the present invention to prevent ball deformation in the event that a stitch is broken.

It is also an object to hold panels together, in their place, and thus not allowing the ball to develop a gap between seems because interior fabric reinforcement patch thus holds the panel in place.

It is yet another object of the present invention to stop water from seeping into the body of the ball particularly during play on wet ground.

It is a still further object of the present invention to prevent the growth of mold inside the ball.

It is still another object of the present invention to ensure that the middle part of a reinforcement patch covers the middle portion of two adjacent panel edges to stop water from coming inside the body of the ball.

It is yet another object of the present invention to prevent water seepage into the ball through any apertures produced by the sewing operation.

It is a still further object of the present invention to reduce the need for an interior thread winding.

Lastly, but not limited hereto, it is an even further object of the present invention to cover sewing needle marks.

Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention.

The recitation herein of desirable objects which are met by various embodiments of the present invention is not meant to imply or suggest that any or all of these objects are present as essential features, either individually or collectively, in the most general embodiment of the present invention or in any of its more specific embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

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:

FIG. 1 illustrates a hexagonal panel and a pentagonal panel and the stitching together of the edges of two hexagonal panels, as for example in the creation of a soccer ball having 32 panels;

FIG. 2 is similar to FIG. 1 except the panels shown are intended for use in the structuring of a volleyball;

FIG. 3 illustrates the interior of a soccer ball prior to its inversion through the last sewn opening and also illustrates the presence of raised, sewn edges;

FIG. 4 is a view similar to FIG. 3 except that it provides a closer detail of the stitching;

FIG. 5 illustrates the shape of patches that are disposed over the interior stitching for seam strengthening;

FIG. 6 illustrates the patches shown in FIG. 5 disposed over the stitching on the interior of a soccer ball;

FIG. 7 illustrates the process employed for the insertion of the bladder;

FIG. 8 illustrates the stitching up of the last seam;

FIG. 9 illustrates a completed soccer ball and particularly illustrates the presence of a valve for filling the ball with air;

FIG. 10 illustrates the interior of a soccer ball produced with 12 pentagonal panels with patches in place;

FIG. 11 is a view similar to FIG. 10 except that the stitching is more clearly visible before the patches are put in place;

FIG. 12 illustrates the interior of a volleyball before the patches are in place;

FIG. 13 illustrates patches of the present invention being applied to the interior of a volleyball;

FIG. 14 it is similar to FIG. 13 except that it illustrates different patch shapes employed in the construction of a desired volleyball; and

FIG. 15 illustrates a finished volleyball.

DETAILED DESCRIPTION

FIG. 1 illustrates to shapes of the panels used in the construction of one form of soccer ball. In this construction, 20 hexagonal panels and 12 pentagonal panels are employed. In particular, there is illustrated hexagonal panel 101 and pentagonal panel 102. Also shown in this figure is the joining together of two of the hexagonal panels by means of stitching 103. It is noted that this stitching structure produces raised stitching 105 on the interior of the ball in its final form (See FIGS. 3 and 4). The presence of this stitching plays a significant role in the present invention. Reinforcement patches used in the present invention comprise any suitable material such as a fabric which is punched out from a large sheet of material. The patch is either a single layered or multilayered fabric which comprises any suitable fabric and may exist in a plurality of shapes depending on the pattern of seams on the ball.

FIG. 2 is similar to FIG. 1 except that it is directed to the construction of a volleyball. In particular, panels 201 and 202 are shown and are shown as being sewn together by way of stitching 203. FIGS. 12 through 15 are also useful to consider along with FIG. 2 as these are also directed to the fabrication of volleyballs.

FIG. 3 illustrates the construction of a soccer ball using the well-known set of 20 hexagons and 12 pentagons. The hexagonal panels are denoted by reference 101 and the pentagonal panels are denoted by reference 102. In particular, the illustration of FIG. 3 shows the construction of a soccer ball in its inverted form prior to the insertion of the bladder. The bladder is the device used for inflation. Of particular note is raised stitching 105 which is present on the inside of the completed soccer ball. Also of note is seam 107. This is the last seam sewn before the soccer ball is inverted. It is through seam 107 that bladder 109 is inserted. See FIG. 7. Also shown in FIG. 3 is the presence of opening 110 in one of the panels. It is within this opening that a valve for the bladder is disposed. FIG. 4 is similar to FIG. 3 except that it is an enlargement and is better descriptive of stitching lines and holes 103. The preferred material for the panels is PU, PVC and TPU with a foam and fabric sandwich. Materials such as PU+Foam+Fabric, TPU+Foam+Fabric etc. are employed. Additionally, multiple layers of fabric instead of one are employed. One could employ any suitable combination of material or materials and any type of sandwich of materials or material for the panels. Likewise, patch material is either a singular layer of fabric impregnated with latex rubber or a combination of multiple layers of fabric impregnated with latex rubber. As with the panels, any suitable material is employed.

FIG. 5 is particularly relevant for the present invention. In particular, there are shown two versions of patches, 150 and 151, intended for being placed over raised threaded portions 105. These are the patches employed in the present invention for all of the purposes recited above. Patch 151 illustrates an embodiment of the invention which is usable because sewn edges are often higher at the corners of each panel. By employing patch design 151, the problem of dealing with wrinkles that are formed at these corners or vertices is solved. Patch design 151 is provided with V-shaped cuts, as shown, so that when patches sit along the seams where three panels meet, the patches do not form wrinkles.

FIG. 6 is also particularly relevant in understanding the structure and features of the present invention. In particular, FIG. 6 illustrates the placement of patches 150 or 151 over sewing seams or edges 105. Note that the presence of overlap between adjacent patches is visible in this figure. It is observed that the ball shown in FIG. 6 represents a soccer ball with 20 hexagonal panels and 12 pentagonal panels. Clearly this figure illustrates the interior structure of a soccer ball prior to its being inverted through open seam 107. A patch of reinforcement fabric 150 is applied over each machine sewn panel stitch joint 105 with adhesive to better secure the stitched panels together. Fabric reinforcement patches cover each adjacently sewn panel joint and thus forms a network of reinforced ridges to further secure the stitching and to withstand pressure from an inflated bladder. This relieves pressure on the machine sewn stitches which are often not strong enough and are not able to withstand bladder pressure. The patches link one panel body to another panel body going across the sewing ridges and bonds them together in such a way that inflated bladder pressure is eliminated on the stitches. The patches act as a strong barrier to absorb pressure and to hold an inflated bladder inside without damage and without tearing any stitches during kicking during play.

FIG. 7 illustrates the exterior of a soccer ball with 20 hexagonal panels and 12 pentagonal panels wherein bladder 109 is in the process of being inserted through seam 107 (see FIGS. 3, 6 and 10). Also visible is opening 110 for an inflation valve. FIG. 8 illustrates the process of stitching up the last seam after bladder 109 is disposed through seam 107. Needle and thread (121 and 120, respectively) are used to close up seam 107. FIG. 9 illustrates completed soccer ball 100. The patches of the present invention are not visible in this Figure.

FIG. 10 is similar to FIG. 6 except that it is directed to the construction of a soccer ball in which only pentagonal panels are used in its construction. Here the pentagonal panels are denoted by reference numeral 104. FIG. 10 also illustrates seem 107 through which an inflatable bladder is inserted before the ball is turned inside out. FIG. 11 is similar to FIG. 10 except that it illustrates the internal structure of a soccer ball prior to placement of patches 150.

FIGS. 12 through 15 represent the structures employed in the present invention when they are used for the construction of a volleyball. A completed volleyball is illustrated in FIG. 15. In the construction of a volleyball differently shaped panels, 201, 202 and 203, are employed. See FIG. 12. In the construction of a volleyball sewn ridges 205 are produced by the sewing operation which, like the construction of a volleyball, is preferably done by machine. It is clear from the illustration that there is shown a volleyball's interior prior to the application of any reinforcing patches and prior to its inversion and the insertion of a bladder. FIG. 13 illustrates the placement of reinforcing patches 250 and 251. As discussed above, patch 251 also includes V-shaped notches to better accommodate the higher ridge portions that occur at panel vertices. FIG. 14 illustrates the placement of patches 260 which are sized to accommodate the network of internal ridges produced in the construction of a conventional volleyball. A completed volleyball 200 is illustrated in FIG. 15.

The reinforcement patches employed in the present invention are made of any suitable fabric or combination of fabrics. Additionally, it is noted that patches are disposed in either singular or multiple layers. Patches comprise a plurality of shapes depending on the stitching pattern employed in ball fabrication. Patches are disposed either in a fashion in which their ends overlap or in which they do not touch. However, in preferred embodiments, overlapping is preferred. The panels themselves comprise any suitable ball material and/or any combination of suitable materials used to make any type of sports ball. While the present description is generally directed to the construction of soccer balls and volley balls, by selecting panels of various shapes it is possible to construct a sports ball of any desired shape. However, spherical shapes more common and are easier to design and fabricate. As described above, particularly with reference to FIGS. 7 and 8, all of the panels are sewn together, except for certain final panels, which are stitched together lastly so as to allow the ball to be turned inside out.

These reinforcement patches work as an interior safety reinforcement layer between one panel to another and thus this whole network of reinforcement patches inside of ball panels make it one uniform interior layer protecting the sewing parts and at the same time attaching themselves to the flat part of panel that reduces pressure on stitches and sewing parts.

In preferred embodiments of the present invention, all of the reinforcing patches connect with each other by overlapping each other, as shown in FIGS. 6, 10 and 14, thus forming a single reinforcing layer underneath (looking from the outside) the sewing ridges of the panels.

In another preferred embodiment, after the ball is completed, a thin adhesive is deployed along the seams; the adhesive then seeps through the seams and ends up on the internal patches. In this way, the adhesive strengthens the connection between adjacent seams along the panel edges. Thus, the internal patches forming a bond of three parts: thread, panel edges and internal patches. This further secures seam strength and at the same time helps to make the seams more waterproof.

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.

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.”

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.

BALL WITH INTERIOR REINFORCEMENT PATCHES

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