DPS Sport Ball

Abstract

A DPS (dual pressure system) sport ball incorporating a special, environment friendly casing that forms an exterior surface of the ball, which is bonded to a multiple lining layers to form a laminated sheet. The laminated sheet is sized, printed, and cut out into specifically designed panels using highly optimized and automated specifically developed machines. The panel cut outs are stitched together using a special stitching machine and a specific, compatible bladder is incorporated in the ball. The partially machine stitched ball is then finally closed by manual stitching and the seams are protected with a special adhesive. Resultantly, due to unique construction materials, their unique arrangement, innovative technology, and highly automated manufacturing processes, the DPS sport ball has advantageous durability, playability, controllability and excellent flight characteristics. The DPS sport ball qualifies under the international standards of match/professional balls at a very competitive price.

1 . A dual pressure system (DPS) sport ball comprising:
 an outer casing forming an exterior surface of the ball;   an inner bladder; and   a multiple lining system, the multiple lining system located between the outer casing and the inner bladder.   
     
     
         2 . The DPS sport ball of  claim 1 , wherein the outer casing is selected from the group consisting of polyurethane (PU), environment friendly PU (EPU), water-borne PU (WPU), PU micro-fiber, PU high solid and thermoplastic PU (TPU). 
     
     
         3 . The DPS sport ball of  claim 1 , wherein the outer casing comprises EPU. 
     
     
         4 . The DPS sport ball of  claim 1 , wherein the multiple lining system comprises at least three lining layers. 
     
     
         5 . The DPS sport ball of  claim 1 , wherein the multiple lining system comprises five lining layers. 
     
     
         6 . The DPS sport ball of  claim 1 , wherein the inner bladder is a specially developed rubber bladder. 
     
     
         7 . The DPS sport ball of  claim 1 , wherein the multiple lining system comprises five lining layers;
 wherein the outer casing comprises a material selected from the group consisting of PU, EPU, WPU, PU micro-fiber, PU high solid and TPU;   wherein each of the five lining layers comprise a material selected from the group consisting of fabric and foam;   wherein each of the five lining layers is bonded to an adjacent lining layer with a bonding material; and   wherein the multiple lining system is bonded to the outer casing to form a panel.   
     
     
         8 . The DPS sport ball of  claim 5 , wherein each lining layer comprises a material selected from the group consisting of fabric and foam; and
 wherein each lining layer is bonded to an adjacent lining layer with a bonding material.   
     
     
         9 . The DPS sport ball of  claim 6 , wherein the bladder is wrapped with a fabric 
     
     
         10 . The DPS sport ball of  claim 6 , wherein the bladder is wound with a thread. 
     
     
         11 . The DPS sport ball of  claim 7 , wherein the bonding material between each lining layer is selected from the group consisting of a natural adhesive and a synthetic adhesive. 
     
     
         12 . The DPS sport ball of  claim 7 , wherein the bonding material between each lining layer comprises a water-based natural adhesive. 
     
     
         13 . The DPS sport ball of  claim 7 , wherein a first lining layer of the multiple lining system comprises a material selected from the group consisting of woven fabric and non-woven fabric, the first lining layer bonded to the outer casing;
 wherein a second lining layer comprises a foam material, the second lining layer bonded to the first lining layer;   wherein a third lining layer comprises a material selected from the group consisting of polyester viscose, polyester cotton, and 100% polyester fabric, the third lining layer bonded to the second lining layer;   wherein a fourth lining layer comprises a foam material, the fourth lining layer bonded to the third lining layer; and   wherein a fifth lining layer comprises a foam material, the fifth lining layer bonded to the fourth lining layer, the fifth lining layer being in proximity to the inner bladder.   
     
     
         14 . The DPS sport ball of  claim 7 , wherein the surface of the panels is debossed. 
     
     
         15 . The DPS sport ball of  claim 7 , wherein the surface of a panel is debossed with two parallel lines. 
     
     
         16 . The DPS sport ball of  claim 13 , wherein the foam material of the second, fourth and fifth lining layer comprises thermoplastic elastomer (TPE) foam. 
     
     
         17 . The DPS sport ball of  claim 13 , wherein each of the outer casing, first, second and third lining layers is of approximately the same surface area; and
 wherein the fourth and fifth lining layers of each panel has a smaller surface area dimension than that of the outer casing, first, second and third lining layers.   
     
     
         18 . The DPS sport ball of  claim 17 , wherein the fifth lining layer has a smaller surface area dimension than that of the fourth lining layer. 
     
     
         19 . The DPS sport ball of  claim 18 , wherein the fifth lining layer are in the form of a patch/es. 
     
     
         20 . The DPS sport ball of  claim 19 , wherein each patch has a surface area in the range of 9.62 cm 2 -19.63 cm 2 . 
     
     
         21 . The DPS sport ball of  claim 19 , wherein each patch has at least one aperture therethrough, each aperture having a surface area in the range of 0.38 cm 2 -3.14 cm 2 . 
     
     
         22 . The DPS sport ball of  claim 19 , wherein each patch has at least one aperture therethrough;
 wherein each patch is round having diameter in the range of 3.5 cm-5 cm; and   wherein each aperture is round having diameter in the range of 0.7 cm-1 cm.   
     
     
         23 . A dual pressure system (DPS) sport ball comprising:
 an outer casing forming an exterior surface of the ball;   an inner bladder; and   a multiple lining system having five lining layers, the multiple lining system located between the outer casing and the inner bladder, an outer surface of the multiple lining system bonded to the outer casing, and an inner surface of the lining system surrounds the inner bladder;   wherein the outer casing is selected from the group consisting of PU, environment friendly PU (EPU), WPU, PU micro-fiber, PU high solid and TPU;   wherein each of the five lining layers comprise a material selected from the group consisting of fabric and foam;   wherein each of the five lining layers is bonded to an adjacent lining layer with a bonding material; and   wherein the water uptake by the ball is less than 0.4%.   
     
     
         24 . A method of manufacturing the dual pressure system (DPS) sport ball of  claim 1  comprising:
 forming a sheet of the multiple lining layers; 
 laminating the outer casing sheet to the multiple lining layers; 
 sizing the sheet; 
 printing panels; 
 cutting the panels; 
 die-punching the panels; 
 machine stitching the panels; 
 incorporating the inner bladder; 
 manually stitching of the remaining portion of the panels to close the ball; and 
 protecting seams of the outer casing. 
 
     
     
         25 . The method of manufacturing the DPS sport ball of  claim 24 , wherein the multiple lining layers are laminated to the outer casing by means of adhesive to form a sheet; and
 wherein the laminated sheet is sized by utilizing specific laser guided presses.   
     
     
         26 . The method of manufacturing the DPS sport ball of  claim 24  further comprising the printing of multiple panels on a sheet by a highly optimized printing machine;
 wherein multiple panels of specific shape and size are printed in a single stroke. 
 
     
     
         27 . The method of manufacturing the DPS sport ball of  claim 24  further comprising debossing on the printed panels by a debossing machine. 
     
     
         28 . The method of manufacturing the DPS sport ball of  claim 24  further comprising the cutting of multiple printed panels in a single stroke by using a cutting machine. 
     
     
         29 . The method of manufacturing the DPS sport ball of  claim 24  further comprising die-punching of the panels by computer numeric controlled (CNC) punching presses to form holes on both sides of the panels for stitching in one stroke. 
     
     
         30 . The method of manufacturing the DPS sport ball of  claim 24  further comprising the stitching of the panels by stitching machine, equipped with a special air pressure system to press and control the panels. 
     
     
         31 . The method of manufacturing the DPS sport ball of  claim 24  further comprising the bonding of additional fourth and fifth layer to each of the panels of the ball with a water based adhesive. 
     
     
         32 . The method of manufacturing the DPS sport ball of  claim 24  further comprising the manual stitching of remaining portion of panels, to close the ball. 
     
     
         33 . The method of manufacturing the DPS sport ball of  claim 24  further comprising protecting seams of adjacent panels;
 wherein the special adhesive is applied manually or by auto-machine. 
 
     
     
         34 . The method of manufacturing the DPS sport ball of  claim 24 , wherein the ball is optionally passed through a molding process, to retain round shape of the ball. 
     
     
         35 . The method of manufacturing the DPS sport ball of  claim 26 , wherein the shape of the printed panel is selected from the group consisting of octagonal, hexagonal, pentagonal, and circular. 
     
     
         36 . The method of manufacturing the DPS sport ball of  claim 31 , wherein the ball is reversed manually and the inner bladder is incorporated.