Football and method of manufacturing same

Abstract

The present development is directed to footballs and to methods for producing the same. More particularly, the disclosure is directed to a technique for readily and inexpensively manufacturing a football. The technique utilizes one or more molding operations and the formation of simulated seams on the ball.

1 . A method of forming a football, the method comprising: 
 forming a bladder adapted for use in a football;    depositing a reinforcement layer on the bladder to thereby form a football carcass;    providing a molding assembly having a molding surface that defines a plurality of recessed channels, each channel adapted to form an outwardly projecting seam;    positioning a layer of a seam material between the molding surface and the carcass, and such that the layer of the seam material is immediately adjacent to a recessed channel;    applying heat to the seam material thereby causing that material to adhere to the carcass and flow into an adjacent recessed channel and form an outwardly projecting seam;    securing a plurality of cover panels to the carcass, wherein adjacent cover panels are separated by the outwardly projecting seam.    
     
     
         2 . The method of  claim 1  wherein the application of heat is accompanied by applying pressure to the seam material positioned between the carcass and the molding surface.  
     
     
         3 . The method of  claim 1  wherein the layer of seam material entirely covers the molding surface.  
     
     
         4 . The method of  claim 1  wherein the seam material is a rubber, and application of heat is sufficient to at least partially vulcanize the rubber.  
     
     
         5 . The method of  claim 1  further comprising: 
 after depositing the reinforcement layer on the bladder to thereby form the football carcass, applying a lacing base to the reinforcement layer.    
     
     
         6 . The method of  claim 5  wherein at least one of the cover panels defines a plurality of apertures, the method further comprising: 
 inserting a lacing into the apertures.    
     
     
         7 . The method of  claim 1  further comprising: 
 applying at least one of (i) ball markings and (ii) striping to the at least one cover panel.    
     
     
         8 . The method of  claim 1  wherein the number of cover panels is 4 to 5.  
     
     
         9 . The football produced by the method of  claim 1 .  
     
     
         10 . A method of forming a football, the method comprising: 
 providing a first molding surface;    molding a bladder on the first molding surface;    forming a fibrous reinforcement layer on the bladder;    applying a lacing base to the reinforcement layer to thereby form a carcass;    providing a second molding surface defining a plurality of recessed channels adapted to form seams in the football;    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;    applying at least one of 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;    applying a plurality of cover panels onto the underlying carcass and alongside the seam;    inserting laces into apertures defined in at least one cover panel; and    applying markings or striping to the cover panels to thereby form the football.    
     
     
         11 . The method of  claim 10  wherein the number of cover panels is 4 to 5.  
     
     
         12 . The method of  claim 10  wherein the cover panels are formed from natural leather or synthetic leather.  
     
     
         13 . The method of  claim 10  wherein the seams extend longitudinally from one end of the carcass to another end.  
     
     
         14 . The method of  claim 10  wherein the lacing base defines a slit and a plurality of apertures adapted to receive a lacing.  
     
     
         15 . The method of  claim 10  wherein the lacing base is formed from a woven fabric.  
     
     
         16 . The football produced by the method of  claim 10 .  
     
     
         17 . A method of forming a football comprising: 
 forming an inflatable bladder;    forming a reinforcement layer on the bladder to thereby form a carcass;    providing a molding assembly sized and adapted to form a football, the molding assembly having a molding surface that defines a plurality of recessed channels extending from one end of the mold to another, opposite end of the mold;    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;    placing the carcass in the molding assembly such that the layer of molding material is disposed between the carcass and the molding surface;    closing the molding assembly;    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;    removing the intermediate football assembly from the molding assembly;    securing a plurality of cover panels to the intermediate football assembly such that an outwardly extending projection separates adjacent cover panels.    
     
     
         18 . The method of  claim 17  wherein the layer of moldable material is selected from the group consisting of butyl rubber and natural rubber.  
     
     
         19 . The method of  claim 18  wherein the step of applying heat and pressure is performed such that the material is at least partially vulcanized.  
     
     
         20 . The method of  claim 17  wherein the layer of moldable material, prior to positioning onto the molding surface is in the form of four panels.  
     
     
         21 . The football produced by the method of  claim 17.