FIELD OF INVENTION
The present invention generally relates to gaming objects and is more
specifically directed to durable gaming objects comprising plurality of layers
maneuvered around an inflatable bladder for enhanced strength, rebound
and superior air retention. The invention further relates to a multi-fuze
object used in games of the like of soccer, netball, handball, rugby etc.
constructed using weather proof materials in a stich-less manner for
enhanced shelf-life and higher performance.
BACKGROUND
A typical gaming object of a pre-defined shape, for example a soccer-ball or a
15 rugby-ball or an unconventional object like a punching bag, usually
comprises at least a bladder or a core on the inside and a cover or casing
that surrounds it. The portion of the ball excluding the cover is
conventionally referred to as the carcass. Historically, gaming objects have of
pre-defined shapes like sports/ game-balls, are usually comprise an
inflatable rubber inner bladder and elastic outer casing (cover). Typically, the
rubber bladder is inflated, and molded under heat and pressure followed by
vulcanization. Of late, the bladder is known to derive strength from
intermediate layer over the bladder forming a layered carcass wherein the
bladder is wound with reinforcing thread which forms a layer of windings.
25 The thread may be dipped in latex or adhesive. The carcass is then covered
with an appropriate cover or casing before the object can be used for the
desired sport or gam.e.
Commercially available inflated game-balls are typically made up of
materials like artificial leather, or thermoplastic polyurethane (TPU) based
30 material, preferably, polyvinyl chloride (PVC) and/ or Polyurethane. These
materials, however, lack durability on rough grounds and their effectiveness
is limited to grassy and soft ground surface. Further, another drawback of
using these materials is their limited durability. With changes in weather
conditions, gaming objects made from PVC or PU get decomposed thereby
having an undesirably short shelf life. Another problem with construction
using leather panels elastically supported by intermediate windings is the
10 non-uniform cushion effect. It is significant to ensure that the gaming object
is appropriately and uniformly cushioned for less impact on foot/ hand while
kicking/ punching/ catching along with appropriate bounce.
Further, it is important to ensure that the outer casing capable of supporting
internal pressurization. The outer casing need not be substantially air
15 impermeable while the inner bladder provides the air barrier such that upon
inflation, the outer casing is stretched tightly over the internally pressurized
rubber inner bladder for high resiliency, rebound and liveliness for use. The
bladders available in the market possess either low air permeability or good
bounce and rebound capabilities, but not both superior resiliency and air
20 retention. This is evidenced by FIFA's (Federation lnternationale de Football
Association) international match-ball standards for gaming objectfball used
in soccer. Their standard for shape retention is less than 2% ball sphericity,
which is challenging, and for ball-rebound is at least 115 cm at roomtemperature
and at least 110 cm at low-temperature, which is also
25 challenging. However, the standard only requires that game-balls inflated to
1 atmosphere of air pressure can lose no more than 25% air pressure after 3
days elapsed time, which is passable by nearly any conventional rubber
bladder material. So far, none of the commercially available gaming objects,
have not been able to achieve a bladder technology that provides for
30 roundness, resiliency and liveliness while also providing superior air
retention.
Inflatable bladders have been known to be produced by several different
processes. A large number of bladders are made by latex rubber dip molding
and curing. Their strengthening is done using nylon or elastic threads wound
around the bladder body lacking much required cushioning effect. These
bladders are popular because, for example, natural rubber latex dipped
10 bladders exhibit very good resilience and playability characteristics.
However, they exhibit poor air retention. Also, when in the inflated but unstretched
state, these bladders form non-ideal shapes. The elements/ layers
of the carcass are generally glued which stiffens the bladder thereby
compromising on quality.
15 The casing typically comprises a plurality of panels attached onto the
bladder, wherein said panels are either machine stitched or hand stitched or
moulded or pasted. Most of the balls marketed in the world today are hand
stitched or machine stitched which tend to have limited productivity due to
dependability on highly skilled workers. There are several other
20 disadvantages for the stitching structure of gaming objects. For example, the
casing panels, being stitched onto the bladder, involve expensive and timeconsuming
manufacturing procedures, yet the resulting gaming object may
not have the optimal roundness. One particularly-pressing problem for
conventional stitched gaming objects is that the casing panels cannot have
25 too sharp a shape as it is difficult for sharp concerns to be adequately
stitched with adjacent casing panels.
Thus, there is a need to develop a stich less gaming object having a strong
carcass providing rebound, air impermeability as well as resilience, uniformly
cushioned with casing that is durable, has a greater shelf life as well as has
30 high performance. The present invention aims to achieve all of the above,
and more, by the aforementioned problems of conventional gaming objects~
SUMMARY OF THE INVENTION
The present invention relates to gaming objects having an inflatable, air
impermeable bladder of a predefined shape, strengthened using a
reinforcing fabric layer wrapped around the bladder and covered with
layered casing for enhanced bounce, superior resilience and constructed in
10 the same shape as that of the bladder.
It is a purpose of the invention to provide for a new and improved gaming
object having high performance and increased durability on rough grounds
characterized by use of rubber on the upper surface as well as the bladder.
Further, the invention provides for increased shelf life of the gaming object
15 characterized by use of weather proof materials. Furthermore, the invention
also enhances shape retention and rebound of the gaming objects by giving
strength to the bladder as well as the casing. Also, the invention aims at
reduction of dependability on scarce skilled labour and provides for stitch
free manufacturing process, thereby increasing productivity.
20 The invention covers a multi-fuze gaming object which comprises of at least
three sections. First section is an air impermeable, inflatable rubber bladder,
wherein said bladder hosts a mouth valve for locking compressed air inside
it. Second section is a multi-layer fabric covering that encloses the bladder,
wherein said covering further comprises at least two layers of fabric. The
25 first layer is affixed on to the bladder along a first axis, say in the horizontal
fashion, while the second layer is affixed on the first layer along a second
axis, say in vertical fashion.
The third section, a layered casing affixed over the multi-layer fabric
covering, is the outermost covering of the gaming object. The layered casing
70 comprises at least two layers, an outer layer and an inner layer which are
affixed together, wherein, the inner layer comprises a rubber blended
foaming sheet and the outer layer, covering the inner layer, comprises a
blended rubber layer affixed to at least one layer of polyester fabric. All the
layers that are formed in each of the three sections of the gaming object are
affixed securely using an adhesive agent.
BRIEF DESCRIPTION OF DRAWINGS
Fig. 1 depicts the carcass and casing of a multi-fuze gaming object
Fig. 2 depicts the top view of a mouth valve embedded in the bladder.
Fig. 3 depicts the linings along different axes of the multi-layer fabric
covering.
Fig. 4 depicts the cross sectional view of the layers of a sports-/game-ball,
15 particularly used in soccer.
Fig. 5 depicts the cross sectional view of the layers of the outer layer of the
casing of the sports-game-ball which is a rubber sheet with polyester fabric.
Fig. 6 depicts the formation of panels using two layers to be joined together
to form the layered casing.
20 DETAILED DESCRIPTION OF THE INVENTION
In the following description, for the purposes of explanation, numerous
specific details are set forth in order to provide a thorough understanding of
the present invention. It will be apparent, however, that the present
invention may be practiced without these specific details or with varied
25 combinations of such details.
The description in ensuing paragraphs cover exemplary embodiments of the
present invention which are described in sufficient detail to enable those
skilled in the art to practice the invention, but other embodiments may be
utilized and logical, mechanical, geometrical, and other changes may be
made without departing from the scope of the present invention. Therefore,
following detailed description is not to be taken in a limiting sense, and the
scope of the present invention is defined only by the appended claims.
Several features are described hereafter that can each be used
10 independently of one another or with any combination of other features.
However, an individual feature might only address one of the problems
discussed above. Some of the problems discussed above might not be fully
addressed by any of the features described herein.
The invention encompasses a multi-layered gaming object fused together to
15 give enhanced performance and gaming experience. The gaming object is
made of two distinct sections viz. a carcass and a layered casing
manufactured for a superior and enhanced gaming experience.
The carcass has a moulded rubber bladder of a predefined shape as its base
and is strengthened by an intermediate layer comprising a multilayer fabric
20 covering affixed on the bladder using an adhesive agent modified to ensure
that the bladder does not stiffen, a problem suffered in conventional gaming
objects. The carcass is vulcanized and rested to provide strength and retain
the shape which when coated with the adhesive agent helps to maintain the
desired rebound.
25 The layered casing that covers the carcass is also made up of rubber as the
primary material to ensure superiority in durability and finishing to the
gaming object. The layers of the casing comprises at least two portions, one
outer layer which covers or wraps an inner layer, affixed together with the
adhesive agent modified for this invention. The outer layer of the layered
30 casing is essentially made from blended rubber polymer which is
strengthened with at least one layer of polyester fabric for better shape
retention. The inner layer of the layered casing is formed of a rubber
blended foaming sheet for the desired cushioning effect while retaining the
bounce. All these materials are weather proof which increases shelf life of
the gaming object and the durability on the rough grounds. The entire
construction of the multi-fuze gaming object is stich-less thereby enhancing
productivity, controlling cost and reducing dependability on skilled labour
force.
In a preferred embodiment, the gaming object is an inflatable game-/sportsball
which is used in games of the like of tennis, soccer, basketball, rugby to
name a few. Alternatively, the invention encompasses alternative gaming
15 objects like punching bags also which are not necessarily game-/sports-balls
but require the same features and properties, none-the-less. The physical
properties like resilience, durability, bounce, cushioning effect, impact shelflife,
abrasion-resistance etc. are absolutely essential for an enhanced gaming
experience especially in national and international level competitions where
20 the relevant gaming object has to not only meet the standards specified by
the tournament/ competition but also give high performance.
As an illustration, Figure 1 of the drawings depicts the preferred gaming
object i.e. sports-/game-ball, which encompasses the multi-fuze structure
having a carcass 100 and a layered casing 106.
As described in the paragraphs above, the gaming object encompassed by
the present invention comprises the core of the carcass is an inflatable
bladder 102 which is the first layer providing shape and surface for building
the sports-/game-ball. In a preferred embodiment, bladder 102 is a hollow
body which has compressed air in it, of predefined shape, depending upon
the kind of sport/ game it is being made for, for instance, round and large for
a soccer-ball, oval and hard for a rugby ball. The bladder 102 is preferably
made up of butyl blended rubber to maximize its air impermeability
properties.
In an embodiment, the bladder 102 composition is a blend of Natural rubber
& halo-butyl, wherein the preferable halogen group is bromine, forming
bromobutyl which helps in air retention. Accordingly, the blend ratio can
10 range from an 80% Natural Rubber and 20% Bromobutyl composition to a
20% Natural Rubber and 80% Bromobutyl composition, depending upon the
amount of air retention desired in the gaming object.
In a preferred embodiment the method of preparation and imparting
strength to the butyl bladder 102 is ensured by curing. As an illustration said
15 method has been explained herein; the blended rubber composition is
converted into thin layer of sheet which may vary from the range of 0.7mm
to 1.00 mm, preferably falling within the range of 0.8mm to 1.Omm. This
sheet is cut into a predefined shape using conventional die cutting machines.
In the uncured bladder a mouth valve 108 is fixed. To balance the weight of
20 the bladder 102 a small rubber compound patch is pasted on opposite side
of the mouth valve 108. This uncured bladder is put in a vulcanization mold,
preferably made up of steel and air is inserted into it. The air pressure in the
closed mold is variable but preferable range is from 5kg to 6kg. The
pressurized bladder then undergoes vulcanization for 5-15 minutes,
25 preferable 8-10 minutes, at a temperature range of 100°C to 200 "C, more
specifically at a range of 145°C to 150°C.
In an embodiment of the invention, the vulcanization mold is characterized
by grooves producing bladders designed with additional rims running
throughout the surface. This gives extra strength and stability to the bladder
30 post vulcanization.
In another embodiment of the invention, the uncured rubber composition is
treated with activators. The step of vulcanizing the rubber composition
chemical reaction typically starts at very slow rate which can take hours. The
activators speed up the cross linking or curing process chemically and help to
get to the final product within minutes. The activators preferred in the
present invention are of the like of Zinc Oxide, Stearic Acid etc., which help
in enhancing the curing rate of the blended composition.
In yet another embodiment, the desired physical properties of the butyl
blended rubber are further enhanced by addition of fillers. The fillers
preferably used are silica, carbon and the like which heighten the physical
15 properties of the bladder like tensile elongation, tear strength etc.,
depending upon the type of gaming object being made.
The invention further encompasses a specially designed mouth valve 108 for
further ensuring air retention as illustrated in Figure 2 of the drawings. The
mouth valve 108 used are those known conventionally for locking
20 compressed air in the bladder 102. In an embodiment of the inventions, a
valve housing is arranged on the inner surface of the bladder, and having a
cavity penetrated through said housing, through which a pneumatic inflation
valve is inserted and fixed. The passage penetrating through the pneumatic
inflation valve receives an inflation needle in the length-wise direction to
25 compress the air inside and prevent the bladder from getting flat.
In a preferred embodiment, after curing and vulcanization process is
complete, the bladder is grinded evenly throughout the surface to open its
pores. This step prepares the bladder for next layer which is affixed using an
adhesive agent, wherein the pores help said adhesive to penetrate into it
30 allowing the next layer to be affixed securely.
In a preferred embodiment, the adhesive agent comprises a water-based
binder mixed with a hardener which encourages early drying of the layers
being fixed. The water-based binders used may be of the like of latex,
essentially being rubber based with 40% water or polyurethane based
adhesive also having significant water content. The binders are mixed with
hardeners in the ratio 0.2% to 0.3%, which facilitate early drying.
The carcass 100 of the sports-/game-ball also comprises a reinforcing
intermediate layer between the bladder 102 and the casing 106 comprising a
plurality of fabric layers 104. The invention encompasses at least two sheets
of fabrics pasted over one another along different axes.
15 In a preferred embodiment, the first lining fabric sheet substantially covers
the bladder in one direction, say vertical i.e. along the y-axis, to form a first
lining. A portion of one first lining of fabric may overlap a portion of another
first lining of fabric to give strength to the edges. The second lining of fabric
is pasted diagonally or horizontally i.e. along the y-axis substantially
20 surrounding the first lining and covering its edges for enhanced strength.
Referring to Figure 3 of the drawing, it is illustrated that the bladder is
covered with the mutli-layer fabric 104 covering to form a strong carcass.
Each layer of fabric is a flexible thin member, preferably made of a cloth,
depending upon the type of sports-/game-ball being prepared. Alternatively,
25 it can be made of other materials, such as, for example, woven fabrics,
unwoven fabrics, threads or other conventional flexible sheet material.
The invention envisages that the first layer of fabric is attached to an
adhesive impregnated bladder by allowing it to stand for 15-50 minutes,
preferably 15, or heating it at 30-60C for 2-12 minutes. This helps in drying
30 the moisture content and ensuring strong adhesion. In an embodiment the
first layer is applied to the bladder, while the bladder is inflated so that the
first layer assumes the same shape.
Once the high strength fabric layer is pasted substantially covering the whole
surface, it is coated with adhesive agent for attaching it to overlapping sheet.
The second layer is then pasted diagonally/ along a different axis to the first
layer to give strength to the edges of the first layer fabric. The purpose is to
reinforce the bladder to retain its original shape and to minimize the
expansion of the bladder up to 1%. The invention, in one embodiment,
envisages, that the bladder with second layer of fabric pasted with adhesive
agent is again coated with the adhesive agent for smooth finishing and is
15 kept to get dry naturally for 15-50 minutes. It can also be made to be given
heat treatment as done for first layer of fabric.
The invention, in a preferred embodiment, encompasses that curing and
vulcanization should be done after applying adhesive agent above the
second layer of fabric for better binding of fabric on bladder. The bladder is
20 put into the vulcanization mold preferably made up of Aluminum and air
pressure is inserted into it which, optimally, in closed a mold ranges from 5
Kg to 15Kg. The bladder is then vulcanized typically for 8-15 minutes at 100-
200 "C, preferably between 140-145°C.
In another embodiment the carcass is dipped or brushed with adhesive
25 agent and rested or heated appropriately (as describe above) for
smoothening the outer surface of the carcass and facilitating better pasting
of the outer casing on it.
The invention covers a layered casing 106 over the carcass of the gaming
object to provide the necessary cushion while ensuring that the durability on
30 rough surfaces and increased shelf life. As illustrated in Figure 4, that depicts
the layers of the outer casing of the invention, there is an outer layer 402
and an inner layer 404 of the casing affixed together, wherein the inner layer
comprises the rubber blended foaming sheet providing the cushioning effect
and the outer layer comprises the rubber blended with polyester fabric for
durability and resilience.
In a preferred embodiment of the invention, as shown in Figure 4, the
rubber blended foaming sheet forming the inner layer 404 of the casing, is
formed from a blend of rubber polymers and co-polymers masticated
together to form a polymer compound. The materials used as co-polymers
for blending may be of the like of Ethylene Vinyl Acetate (EVA), Thermo
Plastic Polyethylene (TPE) etc. The rubber blended compound is blown with
15 a foaming agent, preferably EVA, and converted into a sheet. This sheet
serves dual purpose which includes retaining of bounce and second gives
cushioning effect to the ball. An illustrative inner layer may comprise a blend
of Ethyl Vinyl Acetate (EVA) & Natural Rubber in the ratio of say 90% EVA
and 10% Natural Rubber.
20 In an embodiment, during the mastication process of the rubber blend,
additives are added to enhance its physical properties. The blend may
include additives of the like of fillers like silica and calcium, curatives like
peroxides, accelerators like zinc oxide, stearic acids, processing oils etc.
Along with all or any of the above additives, a blowing agent (ADCL (Azodicar
25 Bonamide) or OBSH (OxydibenzenesulfonyI Hydrazide)) is used to blow the
blended sheet with added foaming agent.
The invention achieves the required cushioning effect by vulcanization of the
rubber blended compound after it is blown with a foaming agent which in
turn converted it into a foaming sheet. In an embodiment, the vulcanization
30 process is the same as that done for the carcass. In another embodiment,
the moulds are not rectangular, but round in shape. Alternatively, the
temperature preferable ranges from 160-165C for a preferable time of 30-50
minutes.
In a preferred embodiment of the invention, the rubber sheet with polyester
fabric, forming the outer layer 402 of the casing, is formed from a layer
polyester fabric 502 laminated onto a rubber layer 504 with adhesive agent.
10 In a preferred embodiment, as illustrated in Figure 5, the uppermost layer of
the sports-/game-ball primarily of rubber. The rubber layer of this laminated
outer sheet formed from a blend of Synthetic and Natural rubbers, with a
preferable thickness of 0.5mm to 1.Omm. The formulation is made to
enhance its physical properties such as high rebound and resilience, high
15 abrasion resistance and all weather resistance property.
In an embodiment of the invention, the rubber compound used is a blend of
Natural &Synthetic Rubber Polymers in 50-50 ratio along with additives such
as silica, titanium, zinc oxide, etc. for enhanced properties.
The invention achieves the desired outer layer properties by several steps.
20 The blended rubber layer 504 is laminated on a polyester fabric sheet 502
which enhances the tearing strength of the rubber layer. The laminated layer
is then vulcanized followed by a second layer of polyester fabric being
laminated with the help of adhesive agent. The laminated sheet is then dried
and moisture of the water-based binder is removed.
25 In an embodiment, the uncured blended rubber compound and a polyester
fabric is put through a calendaring machine. The thin layer of rubber
compound is laminated on the fabric. A transfer paper example Polyester or
Cellophane, preferably having design on it, is pasted on the layer of rubber
compound for making the gaming object presentable. Additionally, such
30 transfer paper also serves as the base for logos or labels or written
inscriptions for purposes of branding and sale. The fabric laminated rubber
sheet is then directly put for vulcanization in a hot press or any other
conventional means and is then kept between two pre heated plates,
preferably made of steel, for vulcanization.
In an embodiment the vulcanization is done at 100-200C, preferably at 130
10 to 135"Cfor 5-50 minutes, preferably for 10 minutes.
In a preferred embodiment, and as illustrated in Figures 1 and 4, the casing
106 of the gaming object is formed of closely laminated smaller panel units,
without and space between adjacent panel units (hereinafter referred to as
panels). As an illustration, where the sport-/game-ball is for soccer, the
15 panels 400 are polygonal in shape, preferably a pentagon, laminated over
the carcass with close spacing between any two adjacent panels.
Alternatively, where the game is basketball, the panels are dumbbell shaped
and comparatively lesser in number.
As illustrated in Figure 6, where the casing comprises polygonal panels, the
20 outer layer 402 i.e. Rubber Layer 504 with polyester fabric 502, laminated
onto the inner layer 404, i.e. Rubber blended Foaming Sheet, is first cut into
desired shape, say pentagon for soccer-ball, separately. The shape for both
inner and outer layers are the same but the outer sheet 402 is cut slightly
bigger than the inner layer 404. The difference in size varies from 2mm to
25 5mm. The panel 400 is prepared by folding the edges of the outer layer 402,
completely wrapping the inner layer from all sides, affixed using the
adhesive agent.
The panels 400 thus formed is then laminated, manually or with machine, in
a stitch less manner on the surface of bladder leaving no space between
30 them. The panels are pasted so as to completely cover the entire carcass.
The finally laminated panels are pressed in a mould, preferably of aluminum,
having pressure of approximately 6 kg to 12 kg, preferably 8-9kg, for 3-10
minutes.
In an embodiment, the panels pasted on the carcass is pressed in a shaping
mould to avoid pealing of panels for better durability. This also helps to
remove unevenness of the panels on the outer surface. In yet another
embodiment, the channels between the panels are run with adhesive agent
to ensure better bonding, low water absorption and for ensuring that the
adjacent panels stick with each other tightly.
In the foregoing specification, embodiments of the invention have been
described with reference to numerous specific details that may vary from
15 implementation to implementation. The specification and drawings are,
accordingly, to be regarded in an illustrative rather than a restrictive sense.
The sole and exclusive indicator of the scope of the invention, and what is
intended by the applicants to be the scope of the invention, is the literal and
equivalent scope of the set of claims that issue from this application, in the
20 specific form in which such claims issue, including any subsequent
correction.

Claim
1. A multi-fuze gaming object, comprising:
an air impermeable, inflatable rubber bladder, wherein
said bladder hosts a mouth valve for locking compressed air
inside the bladder;
a multi-layer fabric covering, enclosing the bladder,
wherein said covering further comprises, at least two layers of
fabric, wherein the first layer is affixed on to the bladder along a
first axis, while the second layer is affixed on the first layer along
a second axis;
a layered casing, affixed over the multi-layer fabric
covering, wherein said casing comprises at least two layers,
further comprising atleast one outer layer and atleast one inner
layer, affixed together,
wherein further, said atleast one inner layer
comprises a rubber blended foaming sheet; and
said atleast one outer layer, covering the inner
layer, comprises a blended rubber layer affixed to
at least one layer of polyester fabric; and
an adhesive agent for affixing securely the layers of said gaming
object.
2. The gaming object as claimed in Claim 1 wherein the bladder is
composed of butyl blended rubber.
3. The gaming object as claimed in Claim 1, wherein the bladder contains
surface pores for the adhesive agent to penetrate and affix securely.
4. The gaming object as claimed in Claim 1, wherein the rubber blended
foaming sheet comprises,
a blend of rubber polymers and co-polymers masticated together;
and
a foaming agent, vulcanized together and converted into a sheet.
5. The gaming object as claimed in Claim 4, wherein the blend further
comprises one or more additives selected from a group of fillers,
curatives, silica, zinc oxide, stearic acids, processing oils and the like.
6. The gaming object as claimed in Claim 1, wherein the adhesive agent
comprises a water-based binder and a hardener.
7. The gaming object as claimed in Claim 1, wherein the layered casing is
formed from smaller panel units, affixed adjacent to each other, to cover
15 the gaming object.
8. The gaming object as claimed in Claim 7, wherein said casing comprises
at least two panel units, laminated adjacent to each other with the
adhesive agent.
9. The gaming object as claimed in Claim 7, wherein each panel unit
20 comprises the at least on outer layer wrapped over the at least one inner
layer.