High Bounce Ball Having Encapsulated Free-Moving Core

Abstract

A ball assembly and the corresponding method used to manufacture the ball assembly. The ball assembly has free-flowing material. The free-flowing material is confined by an inner shell. The inner shell is clear enough so that the free-flowing material can be viewed through the material of the inner shell. The inner shell is encapsulated in a much thicker outer shell. The outer shell is made of a high-resiliency polymer. The outer shell provides the ball assembly with the ability to bounce. Furthermore, the outer shell is preferably clear so that the free-moving material in the center of the ball assembly can be directly viewed through the structure of the ball assembly.

1 . A ball assembly comprising:
 a liquid core;   an inner shell of a first material confining said liquid core; and   an outer shell of a second material surrounding said inner shell, wherein said liquid core is viewable through both said inner shell and said outer shell.   
     
     
         2 . The assembly according to  claim 1 , wherein said outer shell is uniform and lacks any fill opening or plug. 
     
     
         3 . The assembly according to  claim 1 , wherein said outer shell is a polyurethane-based polymer. 
     
     
         4 . The assembly according to  claim 3 , wherein said outer shell is fabricated from a polycarbonate urethane. 
     
     
         5 . The assembly according to  claim 1 , wherein said inner shell is fabricated from a butadiene rubber. 
     
     
         6 . The assembly according to  claim 1 , wherein said outer shell is comprised of at least two shell sections that are bonded together. 
     
     
         7 . The assembly according to  claim 6 , wherein said at least two shell sections are heat bonded together. 
     
     
         8 . The assembly according to  claim 1 , wherein said ball assembly has a diameter and said outer shell has a thickness at least as great as 10% of said diameter. 
     
     
         9 . The assembly according to  claim 1 , wherein solids are free moving within said liquid core. 
     
     
         10 . A ball assembly, comprising:
 an outer shell of a clear polyurethane-based polymer, wherein said outer shell defines an open interior;   an inner shell disposed within said open interior; and   free-moving fill material filling said inner shell.   
     
     
         11 . The assembly according to  claim 10 , wherein said inner shell is clear. 
     
     
         12 . The assembly according to  claim 10 , wherein said outer shell is made of a polymer having a first melting temperature and said inner shell is made of a second polymer having a second higher melting temperature. 
     
     
         13 . The assembly according to  claim 10 , wherein said inner shell is a butadiene rubber. 
     
     
         14 . The assembly according to  claim 13 , wherein said free-moving fill material includes a liquid. 
     
     
         15 . The assembly according to  claim 10 , wherein said ball assembly has a diameter and said outer shell has a thickness at least as great as 10% of said diameter. 
     
     
         16 . A method of fabricating a ball assembly, comprising the steps of:
 molding at least two shell sections from a clear elastomeric polymer;   providing a fluid-filled ball; and   bonding said shell sections together around said fluid-filled ball to form a complete outer shell that encapsulates said fluid-filled ball.   
     
     
         17 . The method according to  claim 16 , wherein said step of bonding includes heat bonding said shell sections together in a heated mold. 
     
     
         18 . The method according to  claim 16 , wherein said step of providing a fluid filled ball includes providing a fluid filled ball with an exterior made from a polymer having a higher melting point than does said shell sections. 
     
     
         19 . The method according to  claim 16 , wherein said shell sections are molded from a polycarbonate urethane.