Game ball having a thin cover and method of making same

Abstract

A game ball is formed by molding a carcass in the final shape of the ball, spraying a mold surface with cover material, inserting the carcass into the mold, and molding the cover material onto the carcass.

What is claimed is:  
     
         1 . A method of making a game ball comprising the steps of: 
 obtaining a mold having an inner surface defining a spherical mold cavity;    forming a spherical carcass;    spraying a cover material onto the inner surface of the mold;    inserting the carcass into the mold cavity;    closing the mold around the carcass; and    molding the cover material onto the carcass.    
     
     
         2 . The method of  claim 1  further including the step of forming the carcass by winding an inflated bladder with at least one thread.  
     
     
         3 . The method of  claim 2  wherein the step of forming the carcass includes the step of molding rubber onto the thread-wound bladder.  
     
     
         4 . The method of  claim 1  wherein the cover material is a polyurethane.  
     
     
         5 . The method of  claim 1  wherein the step of forming the carcass includes molding outwardly projecting pebbles on the outer surface of the carcass.  
     
     
         6 . The method of  claim 1  wherein the step of molding the carcass and the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.  
     
     
         7 . A method of making a game ball comprising the steps of: 
 obtaining a mold having a spherical mold cavity;    forming a spherical carcass;    spraying a cover material onto the carcass; and    heating the cover material and the carcass to bond the cover material to the carcass.    
     
     
         8 . The method of  claim 7  further comprising the steps of inserting the carcass and the cover material into the spherical mold cavity of the mold, closing the mold around the carcass and the cover material; and molding the carcass and the cover material to bond the cover material to the carcass.  
     
     
         9 . The method of  claim 7  further including the step of forming the carcass by winding an inflated bladder with at least one thread.  
     
     
         10 . The method of  claim 9  wherein the step of forming the carcass includes the step of molding rubber onto the thread-wound bladder.  
     
     
         11 . The method of  claim 7  wherein the cover material is a polyurethane.  
     
     
         12 . The method of  claim 7  wherein the step of forming the carcass includes molding outwardly projecting pebbles on the outer surface of the carcass.  
     
     
         13 . The method of  claim 7  wherein the step of molding the carcass and the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.  
     
     
         14 . A method of making a game ball comprising the steps of: 
 obtaining at least one mold having a spherical mold cavity;    forming a spherical carcass;    obtaining a container sized to receive at least one spherical carcass;    placing a cover material into the container;    heating the cover material to a fluid state;    inserting the carcass into the cover material within the container;    removing the carcass with a film of cover material from the container after a predetermined period of time;    inserting the carcass with the film of cover material into the spherical mold cavity of the mold;    closing the mold around the carcass and the film of cover material; and    molding the carcass and the film of cover material to bond the cover material to the carcass.    
     
     
         15 . The method of  claim 14  wherein the step of forming a spherical carcass is performed using a first mold, and wherein the steps of: inserting the carcass with the film of cover material into the spherical mold cavity of the mold; closing the mold around the carcass and the film of cover material; and molding the carcass and the film of cover material to bond the cover material to the carcass, are performed using a second mold.  
     
     
         16 . The method of  claim 14  further including the step of forming the carcass by winding an inflated bladder with at least one thread.  
     
     
         17 . The method of  claim 14  wherein the step of forming the carcass includes the step of molding at least one panel onto the thread-wound bladder.  
     
     
         18 . The method of  claim 17  wherein the at least one panel is formed of a material selected from the group consisting of butyl rubber, natural rubber, sponge rubber and combinations thereof.  
     
     
         19 . The method of  claim 14  wherein the cover material is a polyurethane.  
     
     
         20 . The method of  claim 14  wherein the step of forming the carcass includes molding outwardly projecting pebbles on an outer surface of the carcass.  
     
     
         21 . The method of  claim 14  wherein the step of molding the carcass and the film of the cover material includes molding outwardly projecting pebbles on an outer surface of the cover material.  
     
     
         22 . A game ball comprising a spherical carcass and a one-piece cover, the cover surrounding the carcass and bonded to the carcass without an adhesive, the cover having a thickness less than 0.5 mm.  
     
     
         23 . The game ball of  claim 22  in which the cover is formed of a polyurethane.  
     
     
         24 . The game ball of  claim 22  in which the carcass includes a bladder and at least one thread wound around the bladder.  
     
     
         25 . The game ball of  claim 22  in which the carcass further includes at least one panel molded over the thread-wound bladder.  
     
     
         26 . The game ball of  claim 25  wherein the at least one panel is formed of a material selected from the group consisting of butyl rubber, natural rubber, sponge rubber and combinations thereof.