Methods of Inflation and Play of Lightweight Training Ball with Inner and Outer Layers

This application is a continuation-in-part of PCT Application PCT/US2023/011802 entitled Methods of Inflation and Play of Lightweight Training Ball with Inner and Outer Layers, Filed Jan. 30, 2023 and published as WO2024158399A1 on Aug. 2, 2023, which is incorporated by reference in its entirety. This application claims priority from U.S. Provisional Patent Application No. 63/701,125, entitled Lightweight Inflatable Device for Play or Training and filed Sep. 30, 2024 and incorporated by reference herein in its entirety.

This application is also a continuation-in-part of U.S. patent application Ser. No. 19/253,715, entitled Solid-Filled Ball, filed Jun. 27, 2025, and claims priority from U.S. Provisional Patent Application 63/664,721, filed Jun. 27, 2024. This application also incorporates by reference U.S. patent application Ser. No. 15/296,025, filed Oct. 17, 2016, entitled “Training Ball for Indoor Use and Method for Training With a Lightweight Ball,” which claims priority from U.S. Provisional Application 62/241,882. All of the foregoing are incorporated by reference herein.

The present invention relates to methods of inflating and playing/training with a lightweight inflatable ball and, in particular, to a lightweight ball having an outer layer and an inner bladder.

Athletes who play sports that include hitting or kicking a ball tend to spend many hours training. There are many devices to facilitate training, such as balls attached to bungee cords, balls attached to fulcrums, rolling half-spherical balls and rebounding nets. These devices are often used outdoors or in an indoor stadium or other training space. When such devices are used in most indoor settings, damage to walls, ceilings, other structural components—as well as to related objects, such as lamps, pictures, windows, drinking glasses, etc.—can occur.

As an alternative and in order to limit the possibility of damage, the athlete could use a balloon or beach ball indoors. The exterior of balloons and beach balls do not replicate the exterior of an actual sports ball. Also, the valve, balloon knot and shape can cause the balloon or beach ball to spin lopsidedly and out of balance.

One approach has been to develop a ball that has a shape and weight that allows for an accurate simulation of real ball handling, while limiting the potential damage the ball can do in an indoor environment such as a house. The lightweight ball is inflated with, typically, a straw.

What is needed is an inflation system that doesn't require a separate straw. Also, it would be helpful to have a system that returns the ball to the user after hitting it (with the hand, with the foot, with a bat, tennis racket, hockey stick, etc.), so that the user may train without chasing the ball after hitting it each time.

Embodiments of the present disclosure may include a method for inflating a ball for training and/or play, the method including inflating a ball that may include. Embodiments may also include a flexible outer layer having a diameter. Embodiments may also include an inflatable inner bladder. Embodiments may also include at least most of the outer surface of the inner bladder being bunched up against the inner surface of the outer layer.

Embodiments may also include at least a portion of the bunched up outer surface of the inner bladder being adapted to at least partially change configuration to absorb energy upon impact. In some embodiments, the inner bladder may be inflatable with air and there may be no filler material or stuffing within the inner bladder. In some embodiments, the inner bladder has an unconstrained diameter when fully inflated of at least 1.25 times greater than the diameter of the outer layer.

In some embodiments, the ball including an inflation valve that may be integral with and formed of material of the inflatable inner bladder, the inflation valve having an inflation channel, the inflation valve and the inflation channel extending outwardly from the inner bladder and through an opening in the outer layer, and an inflation tube fixedly secured within the inflation channel, the inflation valve acting as a one-way valve that permits air to flow into the inner bladder through the inflation tube but prevents air inside the bladder from flowing out of the inflation valve.

Embodiments may also include blowing air into the inflatable inner bladder through the inflation tube that may be fixedly secured within the inflation valve until the inner bladder may be filled with air, the inflation tube being sufficiently lightweight that the inflation tube has no noticeable effect to a user on balance and rotation of the ball during training or play.

In some embodiments, the ball further includes a thin, lightweight elastic cord, the elastic cord having a first end secured to the ball and a second end with a strap, the method further including securing the strap to a user. Embodiments may also include hitting the ball outwardly and stretching the elastic cord, such that at least a portion of the bunched up outer surface of the inner bladder at least partially changes configuration and absorbs energy upon impact thereby slowing motion of the ball and reducing stress on the elastic cord. Embodiments may also include after hitting the ball outwardly from the user, pulling the ball back toward the user through contraction of the elastic cord.

In some embodiments, the strap has a connector and the elastic cord may be attached to the connector. In some embodiments, the ball has a ball connector in between the flexible outer layer and the inflatable inner bladder, the flexible outer layer having an opening, and the elastic cord extends through the opening and may be attached at one end to the ball connector to secure one end of the elastic band to the ball.

In some embodiments, the strap may be adjustable and the step of securing the strap to the user includes adjusting the strap to fit the user. In some embodiments, the inflation tube may be entirely within the inflation valve. Embodiments may also include an end of the inflation tube extends out of the inflation valve. In some embodiments, the inflation valve may be adapted to be tucked into the ball, the method further including the step of after inflating the ball, tucking the inflation port including the inflation tube into the ball, in between the outer layer and the inner bladder.

In some embodiments, the ball further includes space in between the inner bladder and the outer layer, a portion of the space being filled with cushioning material in addition to the bunched up outer surface of the inner bladder. In some embodiments, the inflation valve has a one-way channel, the fixed inflation tube being fixedly secured within the one way channel.

Embodiments of the present disclosure may also include a method for inflating a ball for training and/or play, the method including inflating a ball that may include. Embodiments may also include a flexible outer layer having a diameter. Embodiments may also include an inflatable inner bladder, the inner bladder having a diameter when the inner bladder may be unconstrained and inflated that may be sufficiently greater than the diameter of the outer layer such that when the inner bladder may be inside the outer layer, the inner bladder may be adapted to bunch up against the inner surface of the outer layer upon inflation of the inner bladder.

In some embodiments, the outer surface of the inner bladder being bunched up against at least most of the inner surface of the outer layer. In some embodiments, the bunched up outer surface of the inner bladder being adapted to at least partially change configuration to absorb energy upon impact. In some embodiments, the ball including an inflation valve that has a one-way channel and an inflation port including a tube, the inflation port fixedly secured within the one-way channel, the inflation valve acting as a one-way valve that permits gas to blow into the inner bladder through the inflation tube but prevents gas inside the bladder from flowing out of the inflation tube.

Embodiments may also include, forcing a gas into the inflatable inner bladder through the inflation port that may be secured within the inflation channel of the inflation valve, until the inner bladder may be filled with gas, the inflation tube being sufficiently lightweight that the inflation tube has no noticeable effect to a user on balance and rotation of the ball during training or play.

Embodiments of the present disclosure may also include a method for inflating a ball for training and/or play, the method including inflating a ball that may include. Embodiments may also include a flexible outer layer having an inner surface. Embodiments may also include an inflatable inner bladder. Embodiments may also include substantially all of the outer surface of the inner bladder when inflated may be adapted to be bunched up against the inner surface of the outer layer.

Embodiments may also include at least a portion of the bunched up outer surface of the inner bladder being adapted to at least partially change configuration to absorb energy upon impact. In some embodiments, the bunched up inner bladder creates an uneven surface on the outer layer. In some embodiments, there may be no additional material in between the inner bladder and outer layer.

In some embodiments, the inner bladder may be inflatable with gas and there may be no filler material or stuffing within the inner bladder. In some embodiments, the uneven surface of the outer layer may be adapted to reduce the speed of ball as it travels through the air. In some embodiments, the inner bladder may include a metalized film.

In some embodiments, the ball including an inflation valve and an inflation tube fixedly secured within the inflation valve, the inflation valve acting as a one-way valve that permits gas to blow into the inner bladder through the inflation tube but prevents gas inside the bladder from flowing out of the inflation tube. Embodiments may also include, forcing a gas into the inflatable inner bladder through the inflation tube that may be secured within the inflation valve until the inner bladder may be filled with gas.

Embodiments of the present disclosure may also include a method for inflating a ball for training and/or play, the method including inflating a ball that may include. Embodiments may also include a flexible outer layer having a diameter. Embodiments may also include an inflatable inner bladder. Embodiments may also include at least most of the outer surface of the inner bladder being bunched up against the inner surface of the outer layer.

Embodiments may also include at least a portion of the bunched up outer surface of the inner bladder being adapted to at least partially change configuration to absorb energy upon impact. In some embodiments, the inner bladder may be inflatable with gas and there may be no filler material or stuffing within the inner bladder. In some embodiments, the inner bladder has an unconstrained diameter when fully inflated of at least 1.25 times greater than the diameter of the outer layer.

In some embodiments, the ball further includes an elastic cord, the elastic cord having a first end secured to the ball and a second end with a strap, the method further including securing the strap to a user. Embodiments may also include hitting the ball away from the user to stretch the elastic cord, such that at least a portion of the bunched up outer surface of the inner bladder at least partially changes configuration and absorbs energy upon impact thereby slowing motion of the ball. Embodiments may also include after hitting the ball away from the user, pulling the ball back toward the user through contraction of the elastic cord.

Embodiments of the present disclosure may also include a method for inflating a ball for training and/or play, the method including inflating a lightweight device for training and/or play, including a flexible outer layer having an inner surface. Embodiments may also include an inflatable inner bladder inside the outer layer. In some embodiments, the inflated inner bladder when unconstrained by the outer layer having a different shape than the inflated outer layer.

In some embodiments, the outer surface of the inner bladder when inflated being adapted to be bunched up or folded against most of the inner surface of the outer layer. Embodiments may also include upon impact, a portion of the bunched up or folded outer surface of the inner bladder being adapted to change configuration to absorb energy at an area of impact.

In some embodiments, the inner bladder when unconstrained by the outer layer has a maximum dimension at least 1.25 times greater than the maximum dimension of the outer layer. In some embodiments, there may be no filler material or stuffing within the inner bladder. Embodiments may also include and the inner bladder may include boPET.

In some embodiments, the ball including an inflation valve and an inflation tube fixedly secured within the inflation valve, the inflation valve acting as a one-way valve that permits gas to blow into the inner bladder through the inflation tube but prevents gas inside the bladder from flowing out of the inflation tube. Embodiments may also include blowing air into the inflatable inner bladder through the inflation tube that may be secured within the inflation valve until the inner bladder may be filled with gas. Embodiments may also include tucking the inflation valve into a space in between the inner bladder and the outer layer prior to playing with the ball.

In some embodiments, the device may be one of a simulated soccer ball, football, rugby ball, volleyball, baseball, softball, tennis ball, beachball, golf ban, flying disc, and punching bag. In some embodiments, the outer layer may be a soft, tear-resistant, fabric-like material. In some embodiments, the device may be a flying disc including a generally circular upper outer layer, a generally circular lower outer layer, and an interior bladder, the upper and lower outer layers being joined at the edges. In some embodiments, the outer surface of the outer layer may be adapted to receive and retain marking from markers and crayons. In some embodiments, the bunched up or folded inner bladder creates an uneven surface on at least part of the outer layer, the uneven surface adapted to alter movement of the device as it travels through air.

Embodiments of the present disclosure may also include a method for inflating a ball for training and/or play, the method including inflating a lightweight device for training and/or play, including a flexible outer layer having a diameter. Embodiments may also include an inflatable inner bladder, the inner bladder being made of a material and having a maximum diameter when the inner bladder may be unconstrained that may be sufficiently greater than the maximum diameter of the outer layer such that when the inner bladder may be inside the outer layer, the inner bladder may be adapted to bunch up or fold against the inner surface of the outer layer upon inflation of the inner bladder.

In some embodiments, the outer surface of the inner bladder being bunched up or folded against at least most of the inner surf ace of the outer layer. In some embodiments, the bunched up or folded outer surface of the inner bladder being adapted to at least partially change configuration to absorb energy upon impact at an area of impact. In some embodiments, the device has a circumference of at least 68 cm and weighs less than about 3 ounces.

In some embodiments, there may be no filler material or stuffing within the inner bladder. In some embodiments, the ball including an inflation valve having a channel, and an inflation tube fixedly secured within the inflation channel, the inflation valve acting as a one-way valve that permits gas to blow into the inner bladder through the inflation tube but generally prevents gas inside the bladder from flowing out of the inflation tube. Embodiments may also include, forcing a gas into the inflatable inner bladder through the inflation tube that may be secured within the inflation valve until the inner bladder may be filled with gas. In some embodiments, the inner bladder when unconstrained by the outer layer has a maximum dimension at least 1.25 times greater than the maximum dimension of the outer layer. In some embodiments, the device may be one of a simulated soccer ball, football, volleyball, baseball, softball, tennis ball, beachball, golf ball, and flying disc.

Embodiments of the present disclosure may also include a method for filling a lightweight device for training and/or play with air, the method including. Embodiments may also include inflating a lightweight device for training and/or play, including a flexible, tear-resistant outer layer having a diameter. Embodiments may also include an inflatable inner bladder.

Embodiments may also include at least portions of the outer surface of the inner bladder when inflated being bunched up or folded against the inner surface of the outer layer. In some embodiments, the bunched up outer surface of the inner bladder being adapted to absorb energy upon impact at an area of impact. In some embodiments, there may be no filler material or stuffing within the inner bladder.

In some embodiments, the inner bladder has an unconstrained maximum dimension at least 1.25 times greater than the maximum dimension of the outer layer. In some embodiments, the ball including an inflation valve that may be integral with and formed of material of the inflatable inner bladder, the inflation valve having an inflation channel, the inflation valve and the inflation channel extending outwardly from the inner bladder and through the outer layer, and an inflation tube fixedly secured within the inflation channel, the inflation valve acting as a one-way valve that permits air to blow into the inner bladder through the inflation tube but prevents air inside the bladder from flowing out of the inflation valve.

Embodiments may also include blowing air through an opening in the inflation valve and into the inflatable inner bladder through the inflation tube that may be fixedly secured within the inflation valve until the inner bladder may be filled with air, the inflation tube being sufficiently lightweight that the inflation tube has no noticeable effect to a user on balance and rotation of the ball during training or play.

Embodiments may also include tucking the inflation valve into a space in between the inner bladder and the outer layer prior to playing with the ball. In some embodiments, the ball further includes a thin, lightweight elastic cord, the elastic cord having a first end secured to the ball and a second end with a strap, the method further including securing the strap to a user.

Embodiments may also include striking the ball away from the user and stretching the elastic cord, such that at least a portion of the bunched up outer surface of the inner bladder at least partially changes configuration and absorbs energy upon impact thereby reducing motion of the ball. Embodiments may also include after striking the ball away from the user, pulling the ball back toward the user through action of the elastic cord. In some embodiments, the ball has a ball connector in between the flexible outer layer and the inflatable inner bladder, the flexible outer layer having an opening, and the elastic cord extends through the opening and may be attached at one end to the ball connector to secure one end of the elastic band to the ball.

Again, the disclosed concept includes variations, and the optional features noted above may be added to other embodiments of the invention, either alone or in various combinations as appropriate. In particular, optional features with respect to one independent claim, may be included in conjunction with another independent claim, either alone or in combination with other optional features. Consequently, claims that are dependent on one independent claim, may alternatively be dependent on the other independent claims.

A further understanding of the nature and advantages will become apparent by reference to the remaining portions of the specification and drawings.

In one embodiment of the invention, a ball according to the present invention is designed for indoor and in-home use as it is a regulation-sized, spherical ball that weighs slightly heavier than a latex balloon. Alternatively, the ball can also be used competitively in a game or sport.

In a preferred embodiment, the ball is constructed of two or more layers of material that are designed to spin, balance and physically react similarly to a regulation soccer or volleyball that conforms to specifications of a standards body. In one embodiment, the ball is inflated with a standard drinking straw that is inserted into a self-closing valve on the inflation port, the inner bladder being, in one embodiment, a balloon of a metalized film, such as for example Mylar or Mylar-type material. The ball is filled with air, nitrogen, helium or other gas that, in combination with materials and/or ball construction, produce a desired “gravity” or weight.

Considering the drawings of a presently preferred embodiment, a training ballincludes an inner bladder() that has an inflation porttucked within opening. The inflation portmay be pulled out from openingfor inflation or deflation of the ball(). The inflation portallows the bladder() to be filled with air, nitrogen, helium or other gas, as desired. The portincludes a valve, which may be visible or not depending on the manufacturer and material(s) used. As noted, a straw or other device may optionally be inserted into the portto facilitate inflation by blowing into the bladder. If a straw, it may optionally be custom-made for use with the ball.

The ballmay also include design and visuals that may be, for example, lines (printed, molded, intruded or extruded) or other shapes, that give a visual reference to the user and/or give the ball balanced properties when the ball is spinning. In, linesmay be imprinted on or molded into the exterior surface of outer layerof the ball. Although the linesare shown to extend about the circumference in a straight manner, the lines may alternatively be curved and/or another shape. Alternatively, the linesmay be seam lines connecting multiple panels to form the exterior surface of the ball. Indiciawhich, in this case, is a printed colored dot, may be included to give the user a visual effect that may enhance the training such as, for example, allowing the user to better view the spin of the ball during use.

The ball is best produced through a material formation device. This could be but not limited to plastic injection molding, foam molding, vulcanization or other technique specific to manufacturing that accomplishes the size and weight requirements of the training system.

The outer layerof the ballmay have measurements that match the circumference of an actual sports ball. That is, as just one non-limiting example, the training ball may have a circumference of 68-70 cm to correspond to the circumferences of a regular sports ball. The weight of the ball may be varied. There could be, for example, a set of balls that have weights between less than 1 ounce up to about 8 ounces to simulate different levels of “gravity.” The outer layeris typically made of a lightweight synthetic woven material, or other suitable lightweight material.

In one specific embodiment, the training ballincludes a heat seamed, 4-panel inner bladderthat inflates to about 70 cm in circumference. The bladderis made of a material such as Mylar or other material suitable for a bladder. The exterior may be a sewn, 6-panel outer shell that is about 70 cm in circumference when the bladder is inflated. One non-limiting example of a suitable exterior surface is one made of Tyvek 1443R and/or other types of Tyvek or synthetic woven materials or other suitable materials may be used.

Generally, the Tyvek that may be used in some embodiments of the present invention is made with very fine polyethylene fibers bonded by heat and pressure. It is soft and fabric-like, is flexible and has tear resistance. Sewing, gluing, and, to a limited extent, ultrasonic seaming and heat sealing may be used in fabricating materials using these styles. The surface may be corona treated or otherwise prepared such that a user of some embodiments of the present invention may color and customize the surface with permanent marker, water-based marker, and/or crayons and the like. Typically, corona treatment oxidizes the surface and increases the wettability, receptivity, and retention to inks and other materials used in hand-coloring.

In another non-limiting embodiment, the inner bladder has an uninflated dimension of about 7 inches or 17.5 centimeters at its widest point, and a length of about 14 inches or 35 centimeters, not including the length of the inflation port. The inner bladder is then inflatable to a circumference of about 70 cm.