Game ball with synthetic leather cover

Abstract

A game ball having a high end synthetic leather cover formed from a non-woven fiber mat impregnated with polyurethane. In one embodiment, the game ball is a football and the fibers in the backing of the cover material have a denier of about 0.1 or less. In another embodiment, the game ball cover has a dual layer coating to impart to the cover good pebble retention. The first layer has a Shore A hardness of at least about 65, and the second layer surrounding the first layer has a Shore A hardness lower than the hardness of the first layer. The game ball, which can be formed to meet association specifications, has properties of softness and durability comparable to those of a genuine full grain leather game ball.

What is claimed is:  
     
       1. A game ball, comprising: 
       a center,  
       a cover secured over the center, the cover including a backing comprising a fiber reinforced polyurethane material, a first coating layer formed over the backing having a Shore A hardness of at least about 65, and a second coating layer surrounding the first coating layer, the second coating layer having a Shore A hardness which is lower than the Shore A hardness of the first coating layer.  
     
     
       2. A game ball according to claim  1 , wherein the first coating layer has a thickness of about 1-15 mils. 
     
     
       3. A game ball according to claim  1 , wherein the second coating layer has a thickness of about 0.1-10 mils. 
     
     
       4. A game ball according to claim  1 , wherein the sum of the thicknesses of the first and second coating layers is about 1-25 mils. 
     
     
       5. A game ball according to claim  1 , wherein the first coating layer has a Shore hardness of about 65A-60D. 
     
     
       6. A game ball according to claim  1 , wherein the second coating layer has a Shore A hardness of about 30-65. 
     
     
       7. A game ball according to claim  1 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.1 or less. 
     
     
       8. A game ball according to claim  1 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.02 or less. 
     
     
       9. A game ball according to claim  1 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of 0.01 or less. 
     
     
       10. A game ball according to claim  1 , wherein the backing fibers contain at least one material selected from the group consisting of a polyamide and a polyester. 
     
     
       11. A game ball according to claim  1 , wherein the game ball cover has embossed pebbles and the first coating layer has properties of hardness and thickness sufficient to provide the pebbles with a retention level of at least 80% of their molded set. 
     
     
       12. A game ball according to claim  1 , wherein the cover has an embossed texture. 
     
     
       13. A game ball according to claim  1 , wherein the first coating layer has a Sward rocker hardness (ASTM-D2134) of 25-60. 
     
     
       14. A game ball according to claim  1 , wherein the second coating layer has a Sward rocker hardness (ASTM-D2134) of 10-30. 
     
     
       15. A method of making a game ball, comprising: 
       obtaining a game ball center,  
       securing a cover over the center, the cover including a backing comprising a fiber reinforced polyurethane material, a first coating layer formed over the backing having a Shore A hardness of about 65, and a second coating layer surrounding the first coating layer, the second coating layer having a Shore A hardness which is lower than the Shore A hardness of the first coating layer.  
     
     
       16. A game ball, comprising: 
       
         a center,  
       
       
         a cover secured over the center, the cover including a backing comprising a fiber reinforced polyurethane material, a first coating layer having a Shore A hardness formed over the backing and a second coating layer surrounding the first coating layer, the second coating layer having a Shore A hardness which is lower than the Shore A hardness of the first coating layer. 
       
     
     
       17. A game ball according to claim  16 , wherein the first coating layer has a thickness of about  1 - 15  mils. 
     
     
       18. A game ball according to claim  16 , wherein the second coating layer has a thickness of about  0 . 1 - 10  mils. 
     
     
       19. A game ball according to claim  16 , wherein the sum of the thicknesses of the first and second coating layers is about  1 - 25  mils. 
     
     
       20. A game ball according to claim  16 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of  0 . 1  or less. 
     
     
       21. A game ball according to claim  16 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of  0 . 02  or less. 
     
     
       22. A game ball according to claim  16 , wherein the fiber reinforced polyurethane material comprises fibers having an average denier of  0 . 01  or less. 
     
     
       23. A game ball according to claim  16 , wherein the backing fibers contain at least one material selected from the group consisting of a polyamide and a polyester. 
     
     
       24. A game ball according to claim  16 , wherein the game ball cover has embossed pebbles and the first coating layer has properties of hardness and thickness sufficient to provide the pebbles with a retention level of at least  80 %  of their molded set.   
     
     
       25. A game ball according to claim  16 , wherein the cover has an embossed texture.