The present disclosure relates generally to the field of sports balls or game balls. More particularly, the disclosure is directed to footballs, and methods for producing such.
Traditionally, footballs are produced by labor-intensive processes involving numerous operations, many of which are performed by hand. One of the most time consuming and tedious operations involves the assembly of a cover and placement of the cover onto a previously formed football carcass. Typically, a series of cover panels, usually four or five, are sewn together to form a pocket-like assembly. The assembly of sewn panels is then turned inside out, so that the finished face of the panels, i.e. the pebbled surface, is exposed outward. A football carcass is then inserted within the pocket or interior of the assembly, and the assembly closed to thereby contain the carcass. During the insertion operation, efforts are taken to align a valve stem from the carcass bladder with an opening in the cover assembly.
Closure of the assembly is typically performed by lacing together adjacent cover panels that previously formed the opening through which the carcass was inserted. One or more laces are threaded through a collection of holes formed along corresponding edges of two adjacent cover panels that formed the opening. If the holes were not previously formed in the cover panels, a hole forming operation must then be conducted prior to lacing. Lacing is then performed to effectively close the cover panel assembly.
Alternate methods for football construction have included adhesively bonding cover panels to a bladder and then applying lacing through holes in two adjacent panels, as described in U.S. Pat. No. 3,948,518. The use of a preformed lacing assembly was described in U.S. Pat. No. 4,869,504. An overmolding process was described in U.S. Pat. No. 5,181,717. In that overmolding process, a unitary skin or cover is molded onto a premanufactured carcass. Yet another approach was described in U.S. Pat. No. 5,888,157 in which various rubber layers and strips are placed about a wound bladder. The resulting assembly is then heated, preferably in a mold to form the football carcass. Next, a series of cover panels are adhesively attached to the carcass. A region of two adjoining cover panels is selected which is free of adhesive, and lacing is then inserted in corresponding cover holes at that region.
Although satisfactory in certain respects, a need still remains for a manufacturing process that is less labor intensive than the noted methods. Moreover, a need remains for a football that is more durable and less likely to exhibit tearing or peeling of cover panels that are glued to an underlying layer.
The previously noted U.S. Pat. No. 3,948,518 describes an assembly process whereby preformed panels having longitudinally extending ribs are used in forming a football. The outwardly extending ribs separate cover panels that are adhesively attached to the ball carcass. Thus, the ribs resemble “seams” as associated with certain footballs. Although this simplified construction approach provides some advantages over the relatively complicated typical football assembly processes, requiring the use of ribbed, preformed panels introduces other manufacturing complexities such as (i) ensuring that the panels are appropriately aligned on the carcass assembly so that the ribs extend longitudinally across the ball from one end to another, and (ii) ensuring that the alignment between the panels and the carcass is maintained during molding or other football manufacturing operations. In addition, the use of preformed panels with outwardly extending ribs, increases the overall cost of manufacturing the ball since the specific ribbed panels must be premade. After producing the ribbed panels, they must then be further stored or inventoried until their use in the football manufacture. All of these disadvantages add to the expense associated with manufacturing the football. Accordingly, there remains a need for an economical and relatively simple strategy for producing a football.
Additionally, aesthetics and the “feel” of a football are particularly important, especially when the football is used in competitive play. Although the footballs produced according to the noted patents may be acceptable for many applications, a need remains for a football with improved feel, yet which can be inexpensively manufactured.
In a first aspect, the present invention provides a method of forming a football. The method comprises forming a bladder adapted for use in a football. The method also comprises depositing a reinforcement layer on the bladder to thereby form a football carcass. The method further comprises providing a molding assembly having a molding surface that defines a collection of recessed channels. Each channel is adapted to form an outwardly projecting seam on a football when subjected to a molding operation. The method involves positioning a layer of a seam material between the molding surface and the carcass such that the layer of the seam material is immediately adjacent to a recessed channel in the molding surface. The method further comprises applying heat to the seam material thereby causing that material to adhere to the carcass and flow into the adjacent recessed channel and form one or more outwardly projecting seams on the carcass. The method further comprises securing a collection of cover panels to the carcass. The adjacent cover panels are separated by the outwardly projecting seams.
In yet another aspect, the present invention provides a method of forming a football. The method comprises providing a first molding surface and molding a bladder on the first molding surface. The method also comprises forming a fibrous reinforcement layer on the bladder. The method additionally comprises applying a lacing base to the reinforcement layer to thereby form a carcass. The method further comprises providing a second molding surface defining a collection of recessed channels adapted to form seams on the football. The method further comprises applying a layer of a seam material onto at least one of the second molding surface and the carcass such that the seam material is adjacent to a recessed channel. The method further comprises applying heat and pressure to the layer of the seam material to thereby cause the seam material to at least partially flow into the recessed channel and thereby form an outwardly projecting seam. The method further comprises applying a collection of cover panels onto the underlying carcass and alongside the seam. The method further comprises inserting laces into apertures defined in at least one cover panel. And, the method comprises applying markings or striping to the cover panels to thereby form the finished football.
In yet another aspect, the present invention provides a method of forming a football comprising forming an inflatable bladder. The method also comprises forming a reinforcement layer on the bladder to thereby form a carcass. The method additionally comprises providing a molding assembly sized and adapted to form a football. The molding assembly has a molding surface that defines a collection of recessed channels extending from one end of the mold to another opposite end of the mold. The method further comprises positioning a layer of a moldable material onto the molding surface such that the entirety of the molding surface is covered by the moldable material. The method further comprises placing the carcass in the molding assembly such that the layer of molding material is disposed between the carcass and the molding surface. The method additionally comprises closing the molding assembly. And, the method comprises applying heat and pressure to the carcass and the moldable material such that the material flows into the recessed channels defined in the molding surface to thereby form outwardly extending projections along the resulting intermediate football assembly. The method further comprises removing the intermediate football assembly from the molding assembly. And, the method comprises securing a collection of cover panels to the intermediate football assembly such that an outwardly extending projection separates adjacent cover panels.
There has thus been outlined, rather broadly, some of the more important features of the footballs and their methods of manufacturing disclosed herein in order that the detailed description thereof that follows may be better understood. There are, of course, additional features of the disclosure that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the football and its manufacture disclosed herein in detail, it is to be understood that the disclosure is not limited in this application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The disclosed football and related method is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of descriptions and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present development. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the disclosure.
Other objects and advantages of the development disclosed herein will be evident to one of ordinary skill in the art from the following description and figures, in which:
The preferred embodiment football and related method of manufacturing provides a significantly improved strategy for inexpensively producing a durable and wear resistant football exhibiting excellent aesthetics and “feel.”
A more complete understanding of the components, processes and apparatuses disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present development, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.
Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings, and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.
In a preferred embodiment, the present invention provides a unique and economical process for manufacturing a football and the football produced from that process. This process involves the use of particular molds that define channels or recesses that during manufacture of the football, form seams that extend longitudinally from one end of the football to the other. The seams are formed from thin layers of a material, generally referred to herein as seam members, that upon molding, flow into the channels or recesses defined in the mold surface and form outwardly projecting seams on the football or intermediate football. The thin layers can be either placed on the football carcass prior to molding, or placed in the mold, generally over the channels and recesses prior to ball molding. After formation of the longitudinally extending and outwardly projecting seams, cover panels are then applied onto the football. This unique strategy entirely avoids the problems and additional costs associated with using preformed panels with outwardly extending ribs that must be aligned on the ball, maintained in alignment during ball manufacture, and stored or inventoried prior to ball manufacture.
Referring to
Referring to
Upon attachment of the cover panels to the seam strips and underlying carcass or foam layer, additional finishing components can be included in the assembly to complete the preferred embodiment football. Lacing is inserted through the noted sets of apertures, i.e. 75c, 44, and 75d. In addition markings, indicia, labels, striping, logos, and/or other designations can be applied to the football.
Various preferred methods of manufacturing are also provided. These improved manufacturing methods are particularly suited for high volume commercial production objectives in which it is desirable to inexpensively produce a high quality, low defect, football with consistent properties such as attractive aesthetics and good “feel.”
Referring to
Next, a fibrous reinforcement layer is formed about the bladder layer. The fibrous layer can include a collection of woven filaments or strand material extending throughout a polymeric binder or matrix. This is designated as step 200. The fibrous layer is formed by winding one or more fibers, natural or synthetic, in a known manner about the bladder layer. Winding is generally performed while the bladder is at least partially inflated. It is also contemplated to utilize a non-wound fibrous layer either alone or in conjunction with a wound layer.
A lacing base, such as for example utilizing a layer of fabric is positioned and/or secured on the fibrous reinforcement layer. This is designated as step 300. The lacing fabric base preferably includes a slit-like opening and apertures for acceptance of the laces. The resulting assembly is referred to herein as the carcass and designated as 400. The lacing base can be formed from nearly any material including for example, a nonwoven material or fabric. The base can also be formed from a thin planar member such as including a cellulose material. Alternately or in addition, polymeric materials may be used to form the lacing base.
Application of the seam material to the mold or carcass is designated as step 600. Preferably, this can be performed by placing various strips or thin layers of seam material or seam members into a carcass mold. The strips are placed in or upon the mold so that they are adjacent, and preferably overlie the channels defined in the molding surface. The carcass with the fibrous reinforcement layer or the optional additional foam layer, is positioned within the carcass mold containing the strips. Alternately, the strips are placed upon the carcass. The outwardly projecting seams are then formed by molding the resulting assembly. This is designated as step 650. Preferably, the seams are formed by heat and pressure applied to the mold containing the carcass and strips or seam precursor, thereby securing the strips to the carcass and at least partially melting the seams and causing the material to flow into channels defined in the molding surfaces to thereby form the noted seams. Preferably, the seams project outwardly or protrude from the outer surface of the carcass. The seam materials can include any material that upon heating to the molding temperature, flows, or otherwise tends to bond and secure the resulting seams to the underlying carcass. Preferably, the seam material is an elastomer or rubber. The seam materials can include additional adhesives, elastomers, rubbers as previously noted, or thermally activated materials. Preferably, the seam materials include a coloring agent or pigment such as carbon black so that the resulting seams in the finished football are black in color. During the application of heat and pressure, it is preferred that the rubber materials in the carcass being formed undergo vulcanization. A preferred molding configuration for forming seams is depicted in
Most preferably, in yet another alternate embodiment, after forming the football carcass, i.e. bladder with windings, one or more rubber or other moldable elastomer layers are placed in, and generally upon, the molding surfaces of a mold. As will be recalled, preferably, the molding surface defines a plurality of channels or depressions that enable the formation of the seams described herein. Preferably, the rubber layers cover the entirety of the molding surface. The carcass is then placed in the mold such that the rubber layer(s) are disposed between the carcass and the molding surface. Alternately, the rubber layer(s) could be placed upon or otherwise about the carcass outer surface, and the resulting assembly placed in the mold. Upon application of sufficient heat and pressure, the rubber material flows into the channels or depressions defined in the molding surface and thereby forms the noted seams. Although the term “rubber” is used in referring to the layer(s) of material placed in, and generally upon, the molding surfaces, it will be understood that this material corresponds to the previously described seam material. Accordingly, this material can include any material that upon heating to the molding temperature, flows, or otherwise adopts the shape of the channels or depressions defined in the molding surface.
After formation of outwardly projecting seams, i.e. step 650 in
In certain embodiments, the cover panels and/or the seam materials are applied onto a “wet” or flowable layer of the optional foam material. The cover panels are secured or otherwise laminated to the carcass. Preferably, this is achieved by heating or subjecting the assembly to a molding operation to securely bond the cover panels to the foam layer, as that layer sets. Application of heat and/or pressure is preferably used to laminate the cover panels to the carcass. This is designated as step 800, and the intermediate football that is formed is designated as 900.
Referring to
Lastly, lacing is inserted into the apertures. This is designated as step 1000. A wide array of lacing types and configurations can be used. Prior art laces or lacing configurations can be used. However, it is preferable in certain embodiments that the lacing exhibit a frictionally enhanced surface to promote gripping.
Throughout the process, a valve body previously formed in the bladder in a conventional manner, is aligned and exposed through an aperture in the cover assembly. The valve aperture can be formed in the designated cover panel at any point in the process.
Ball markings and striping are applied. This is designated as step 1100. Conventional ball markings and/or striping can be utilized. In certain embodiments, an integral one-piece striping member can be affixed to the outer surface of the ball, or applied within channels defined along the ball cover. Such striping members can also be sewn or stitched to the cover panels. The final football is designated as 1200.
As will be apparent to persons skilled in the art, various modifications and adaptations of the structures and methods described above will become readily apparent without departure of the spirit and scope of the development disclosed herein. The above description merely provides a disclosure of particular embodiments of the development and is not intended for the purposes of limiting the same thereto. Rather, it is recognized that one skilled in the art could conceive alternative embodiments that fall within the scope of the development.