Inflatable game ball and method for manufacturing the same

Abstract

An inflatable game ball includes an inflatable bladder, a winding layer surrounding the bladder, a rubber inner carcass layer surrounding the winding layer, and a cellular outer carcass layer surrounding the inner carcass layer. During manufacture of the game ball, the bladder is first inflated. A plurality of yarns are wound around the inflated bladder to form the winding layer, on which the inner carcass layer is molded. A plurality of patches are interconnected by stitching to form a bag that has an opening. The bag is reversed, and the bladder is deflated so that an assembly of the bladder, the winding layer, and the inner carcass layer can be inserted into the reversed bag via the opening. The opening in the bag is then closed by stitching so as to form the outer carcass layer on the inner carcass layer.

I claim:  
     
         1 . An inflatable game ball comprising: 
 an inflatable bladder with an air valve;    a winding layer surrounding said bladder;    a rubber inner carcass layer surrounding said winding layer; and    a cellular outer carcass layer surrounding said inner carcass layer and including a plurality of patches, each adjacent pair of which are fastened to each other by stitching along outer peripheries thereof, said air valve extending through said winding layer and said inner and outer carcass layers, and being exposed outward from said outer carcass layer to permit inflation of said bladder.    
     
     
         2 . The inflatable game ball as claimed in  claim 1 , wherein said inner carcass layer is made of natural rubber.  
     
     
         3 . The inflatable game ball as claimed in  claim 1 , wherein said inner carcass layer is made of synthetic rubber.  
     
     
         4 . A method for manufacturing an inflatable game ball, the method comprising the steps of: 
 blowing air into an air valve on an inflatable bladder so as to inflate said bladder;    winding a plurality of yarns around said bladder, and subsequently coating said yarns with glue so as to form a winding layer that surrounds said bladder, with said air valve extending through and being exposed outward from said winding layer;    molding a rubber inner carcass layer that surrounds said winding layer, with said air valve extending through and being exposed outward from said inner carcass layer;    interconnecting a plurality of patches by stitching along outer peripheries thereof so as to form a bag that has an opening, one of said patches having a hole formed therethrough;    reversing said bag so as to conceal the stitched outer peripheries of said patches within said bag;    deflating said bladder and inserting an assembly of said bladder, said winding layer, and said inner carcass layer into said bag via said opening, with said air valve extending into said hole; and    closing said opening in said bag by stitching so as to form an outer carcass layer on said inner carcass layer.