Method for manufacturing a robust tethered ball

Abstract

A method and article of manufacture are disclosed for manufacturing a robust tethered ball. The method includes steps of: (a) providing an elastic tether; (b) cutting the tether to a desired length so that the tether has an end portion that extends from an inner portion of the tether to an end of the tether; (c) folding the end portion of the tether straight back upon the inner portion of the tether so that the end portion of the tether including the end of the tether lies parallel to the inner portion of the tether; (d) securing the end portion of the tether to the inner portion; (e) coating the end portion of the tether including the end of the tether and the inner portion of the tether with an adhesive to provide adhesion between the tether and a liquid polymer; and (f) forming a solid ball on the end portion of the tether from the liquid polymer that completely includes the end portion of the tether, the end of the tether, and the inner portion of the tether.

1 . A method comprising steps of: 
 (a) providing an elastic tether;    (b) cutting the tether to a desired length so that the tether has an end portion that extends from an inner portion of the tether to an end of the tether;    (c) folding the end portion of the tether straight back upon the inner portion of the tether so that the end portion of the tether including the end of the tether lies parallel to the inner portion of the tether;    (d) securing the end portion of the tether to the inner portion;    (e) coating the end portion of the tether, the end of the tether, and the inner portion of the tether with an adhesive to provide adhesion between the tether and a liquid polymer; and    (f) forming a solid ball on the end portion of the tether from the liquid polymer that completely includes the end portion of the tether, the end of the tether, and the inner portion of the tether.    
   
   
       2 . The method of  claim 1  wherein the tether comprises a length of elastic shock cord having a core of rubber bands surrounded by a cover of braided nylon.  
   
   
       3 . The method of  claim 1  wherein the liquid polymer is cured into a urethane foam.  
   
   
       4 . The method of  claim 3  wherein the adhesive comprises an isocyanate catalyst.  
   
   
       5 . The method of  claim 1  further comprising a step of applying a wear resistant coating to an outer portion of the tether extending outside the solid ball.  
   
   
       6 . The method of  claim 5  wherein the wear resistant coating comprises tetrahydrofuran, polyurethane polymer, and methyl ethyl ketone.  
   
   
       7 . The method of  claim 6  wherein the wear resistant coating comprises about 15 percent tetrahydrofuran by weight.  
   
   
       8 . The method of  claim 6  wherein the wear resistant coating comprises about 20 percent polyurethane polymer by weight.  
   
   
       9 . The method of  claim 6  wherein the wear resistant coating comprises about 65 percent methyl ethyl ketone by weight.  
   
   
       10 . The method of  claim 1  wherein step (d) comprises securing the end portion of the tether to the inner portion of the tether by a hog ring.  
   
   
       11 . The method of  claim 1  wherein step (d) comprises lashing the end portion to the inner portion of the tether by a wire.  
   
   
       12 . The method of  claim 1  wherein step (d) comprises lashing the end portion to the inner portion of the tether by a cord.  
   
   
       13 . The method of  claim 1  further comprising a step of curing the liquid polymer to a density of between 18 and 32 pounds per cubic foot to produce a realistic sound when a bat strikes the solid ball.  
   
   
       14 . An article of manufacture comprising: 
 a tether having an end portion that extends from an inner portion of the tether to an end of the tether wherein the end portion of the tether is folded straight back upon the inner portion so that the end portion of the tether including the end of the tether lies parallel to the inner portion of the tether and wherein the end portion of the tether, the end of the tether, and the inner portion are coated with an adhesive to provide adhesion between the tether and a cured liquid polymer; and    a solid ball formed from the cured liquid polymer wherein the solid ball completely includes the end portion of the tether, the end of the tether, and the inner portion of the tether.    
   
   
       15 . The article of  claim 14  wherein the tether comprises a length of elastic shock cord having a core of rubber bands surrounded by a cover of braided nylon.  
   
   
       16 . The article of  claim 14  wherein the liquid polymer is cured into a urethane foam.  
   
   
       17 . The article of  claim 14  wherein the adhesive comprises an isocyanate catalyst.  
   
   
       18 . The article of  claim 14  further comprising a wear resistant coating applied to an outer portion of the tether extending outside the ball.  
   
   
       19 . The article of  claim 18  wherein the wear resistant coating comprises tetrahydrofuran, polyurethane polymer, and methyl ethyl ketone.  
   
   
       20 . The article of  claim 14  wherein the liquid polymer is cured to a density of between 18 and 32 pounds per cubic foot to produce a realistic sound when a bat strikes the solid ball.