INFLATABLE PLAY BALL

STATEMENT OF RELATED CASE [0001] This application claims the benefit of United States continuation-in-part Application Serial No. 11/854,030, filed September 12, 2007, which claims the benefit of United States Patent Application Serial No. 11/534,905, filed on September 25, 2006, which claimed the benefit of and priority to United States Provisional Patent Application Serial No. 60/825,553, filed on September 13, 2006, all of which are hereby incorporated by reference. BACKGROUND ART

[0002] This application generally relates to the field of balloon balls.

[0003] Balloon balls, for example, those sold under the trade name "Balzac", have a fabric casing over a balloon that is inflated to conform to the shape of the fabric coating. U.S. Patent No. 4,834,392 discloses one such example. The balloon is inserted into an opening in the casing. Upon inflation, the elasticity of the balloon creates a much higher pressure than a typical ball with a non-expanding bladder. This is the reason why, unlike a football or basketball, no pump is required, and a balloon ball can be inflated by mouth.

[0004] Unlike a beach ball, which can be inflated by mouth, however, balloon balls have a higher number of pounds per square inch and bounce much higher. The balloons generally deflate over long periods of time and tend to sag after a day or two. This presents issues for retailers in displaying the products as well as the consumers who cannot leave the balloon balls inflated without deterioration of play value and the replacement of the balloon. [0005] There exists a need, therefore, to provide balloon balls that are configured to readily permit re-inflation or replacement of the internal balloon.

SUMMARY OF THE INVENTION

[0006] Provided are improved balloon balls that readily permit re-inflation or replacement of the internal balloon as compared to conventional designs. In one aspect of the present invention, balloon balls are provided that comprise an outer casing having an opening for the insertion of a balloon and at least one vent to permit evacuation of air or gas from the outer casing while the balloon is being inflated. The outer casings are generally non-porous to air or gas. The vent can be a traditional inflation valve, such as that found on a beach ball. Other examples of vents include check-valves, mesh, holes, flaps affixed with hook and loop fasteners over openings, and the like. The size and shape of the vent can be chosen to permit retrieval of balloon fragments should the need arise.

[0007] In accordance with one aspect of the present invention, an inflatable play ball includes an outer casing formed of a flexible material that is substantially non-porous which assumes a desired play ball configuration when expanded, the outer casing having a first opening and at least one second opening and a balloon formed of an elastomeric material, the balloon having a closeable opening and being inside the outer casing.

[0008] All of the openings can optionally include closure mechanisms.

[0009] In accordance with another aspect of the present invention, a method of inflating a play ball is provided. One aspect of the method includes the steps of: supplying an outer casing formed of a flexible material that is substantially non-porous, the outer casing comprising an opening, a closure, and at least one vent therein; supplying a balloon formed of an elastomeric material and comprising a closeable opening; inserting the balloon in an uninflated state through the opening and into the outer casing while leaving the closeable opening outside of the outer casing; inflating the balloon by supplying air or a gas through the closeable opening; evacuating air from the outer casing through the at least one vent as the balloon inflates; closing the

closeable opening upon inflation of the balloon; inserting the closeable opening within the outer casing; and substantially sealing the opening with the closure. This causes a ball to assume a desired play ball configuration.

[0010] Another aspect of the present invention involves providing a kit that includes an outer casing formed of a flexible material that is substantially non-porous which assumes a desired play ball configuration when expanded, the outer casing having a first opening and at least one second opening and a balloon in its uninflated state formed of an elastomeric material adapted to be placed inside the outer casing through the first opening.

BRIEF DESCRIPTION OF THE DRAWINGS [0011] Figure 1 illustrates a schematic of the play ball in accordance with one aspect of the present invention with a cut-away to show an inflated balloon inside an outer casing.

[0012 J Figure 2 illustrates an inflation valve.

[0013] Figure 3 illustrates an uninflated balloon which is inserted into an outer casing.

[0014] Figure 4 illustrates another aspect of the play ball. [0015] Figure 5 illustrates another embodiment of the play ball.

[0016] Figure 6 illustrates a kit in which the play ball is provided.

[0017] Figure 7 illustrates another embodiment of the play ball.

[0018] Figure 8 illustrates another embodiment of the play ball.

DETAILED DESCRIPTION [0019] One or more aspects of the present invention provide an inflatable play ball including an outer casing formed of a flexible material that is substantially non-porous to air, which, when the outer casing is fully expanded, assumes a desired play ball configuration. The outer casing of some aspects comprises an opening to permit insertion into the outer casing of a balloon in its uninflated state, a closure that is operable to substantially seal the opening during use of the ball,

and at least one vent therein to permit evacuation of air from the outer casing as the balloon is inflated. The balloon of various aspects is formed of an elastomeric material, the balloon comprising a stem which initially projects through the opening and is then outside of the outer casing to permit inflation of the balloon within the outer casing, after which, the stem is tied and inserted within the outer casing.

[0020] In another aspect, a method of inflating a play ball includes: supplying an outer casing formed of a flexible material that is substantially non-porous to air, the outer casing comprising an opening, a closure, and at least one vent therein; supplying a balloon formed of an elastomeric material and comprising a stem; inserting the balloon in an uninflated state through the opening and into the outer casing while leaving the stem outside of the outer casing; inflating the balloon by supplying air or a gas through the stem; evacuating air from the outer casing through the at least one vent; tying the stem upon inflation of the balloon; inserting the stem within the outer casing; and substantially sealing the opening with the closure; thereby forming a desired play ball configuration. [0021] Referring now to Figures 1 to 4, there is illustrated an inflatable play ball and its components in accordance with the present invention. The ball comprises an outer casing 10 that is non-porous and an inflated balloon 12 which conforms to the shape of the outer casing. The outer casing 10 can also be substantially non-porous, for example, if stitching is used to hold various parts of the outer casing 10 together. When the outer casing 10 is expanded, as shown, a desired configuration of a play ball is provided. The casing can assume any shape and size as needed. For example, the play ball can be a football, a soccer ball or any other type of ball or configuration. The outer casing can also inflate to non-spherical, odd shapes, for example, the shape of a character. The outer casing 10 is substantially non-porous to air. The outer casing may be formed of many types of materials. In one embodiment, it may be desirable

to use a polymeric plastic film, such as a polyvinyl chloride film used for beach balls. In another embodiment, it may be desirable to coat a fabric material to make the fabric material non- porous. The coating can be placed either within the outer casing 10 or on the exterior surface of the outer casing. The coating can be sprayed on. In accordance with one aspect of the present invention, the outer casing is a fabric and an impermeable membrane is attached or applied to the fabric. Of course, the impermeable membrane can be attached or applied to any flexible material.

[0022] At least one vent 14 is provided in the outer casing 10 to permit evacuation of air from the outer casing 10 while the balloon is inflated within the casing. The vent can be a traditional inflation valve 16 such as that found on a beach ball. This is also referred to herein as a port and a plug combination. Non-limiting examples of vents used in various aspects include check-valves, mesh, holes, flaps affixed with hook and loop fasteners over openings, and the like. Further aspects have the at least one vent provided a covering to help protect the integrity of the balloon during play. [0023] Figure 3 shows the balloon 12 of some aspects of the invention, in its uninflated state. The balloon of various aspects is formed of a thin elastomeric material having a stem 13 which initially projects through an opening 11 in the outer casing 10, as shown in Figure 4. The opening 11 in one or more aspects can be a slit or any other suitable passage in the outer casing 10. In an embodiment of a beach ball, the opening can be an inflation valve sized to accommodate passage of an uninflated balloon. After the balloon has been inflated, the stem 13 can be tied off and inserted within the outer casing 10. In one or more embodiments, the opening 11 has a closure 17 to retain the balloon stem within the outer casing and substantially seal the opening during use of the ball. The closure over opening 11 can be a zipper, any type of

valve, a plug, adhesive mesh or any other type of closure. Any of the closure mechanisms discussed herein can be used to close the openings 1 1 and 14 in the outer casing 10. [0024] As the balloon 12 inflates in some embodiments, the at least one second opening 14, if closed, is opened and air from inside the outer casing 10 is evacuated from the outer casing 10. Once the balloon 12 is inflated, the stem 13 can be knotted and the second opening 14 closed with flap 15. The knotted stem 13 can be placed inside the outer casing 10 and the first opening 11 can also be closed via any of the previously described methods.

[0025] When a balloon is inflated inside a fabric case, the air between the partially inflated balloon and the case escapes through the case. With the impervious case of the present invention, air tends to get trapped between the partially- inflated balloon and the case, and may create undesirable air pockets. A single vent or hole in the case at the bottom (opposite the slit where the balloon is inflated) is not always sufficient to prevent the formation of these air pockets. Thus, in some embodiments, it is preferred to have several small holes or openings in addition to the slit where the balloon is inflated. These small holes or openings are punched in the vinyl case to prevent the formation of these air pockets.

[0026] For example, if one thinks of an inflated balloon inside a casing in accordance with the present invention, as a globe, with a balloon inserted in a slit in the casing at the North Pole, it is believed that a total of about 6 small holes, each no more than 1/4 inch in diameter, spaced along what would be the Tropic of Cancer and the Tropic of Capricorn, provide optimum results.

[0027] Accordingly, it is preferred that the casing use as much of the impervious vinyl case as possible to prevent air from escaping from the inflated balloon. Therefore, although a large balloon is inserted in the slit for inflation, it is preferred that the slit in which the balloon is inserted be as small as possible to leave only a small area where the balloon is not covered by

the vinyl. Therefore, it is preferred to heavily reinforce the slit so that a large balloon can be partially pulled inside the case (while of course leaving the neck sticking out for inflation) without tearing the slit in the vinyl.

[0028] Figure 5 shows this additional embodiment of the present invention. The balloon has an opening 23 that extends through the first opening 21 of the casing. In this embodiment, a plurality of second openings 24, 26 and 28 are provided to allow air to be evacuated from between the casing and the balloon as the balloon is inflated. More or less second openings can be provided. Additionally, the second openings can be closeable as described previously. [0029] Figure 6 illustrates a kit form of the present invention. A package 30 is provided. The outer casing 32 and one or more balloons 34 and 36 are provided inside the package 30.

[0030] In accordance with another aspect of the present invention, the outer casing 10 and the balloon 12 are provided in a single package for sale. Upon usage, the balloon 12 is inserted into the outer casing 10 and air is introduced into the balloon 12. Any air in the outer casing 10 is evacuated through the at least one second opening in the outer casing, and the balloon inflates to cause the outer casing 10 to assume a shape.

[0031] In accordance with a further aspect of the invention, there are no loops attached to the outer casing.

[0032] In various embodiments of the invention, the opening is reinforced. This has the benefit, among other things, of protecting the opening from tearing during insertion or removal of a balloon.

[0033] Further embodiments of the invention have at least one additional section heat sealed onto the outer casing of the ball. Because the play ball can be made of a non-porous inflatable material, it is possible to add on another section that is heat sealed into a fully enclosed area (with no holes). In embodiments of this sort, a conventional inflatable valve may be used to

inflate the protrusion, at less pressure than the balloon ball. Embodiments of these types can result in a bouncing play ball with arms or legs that are decorative, or a protrusion that a child could hold onto, while retaining the high pressure characteristics of the balloon ball. [0034] Figure 7 illustrates an embodiment of the invention having additional sections 38 heat sealed onto the outer casing 10 of the ball. The embodiment displayed in this example is a mock-human form having arms and legs 38 as additional section. The arms and legs 38 have inflation tubes 40 for inflating the sections. The inflation tubes 40 can be recessed into the additional sections 38 after inflation. The face on the outer casing 10 is solely an example of a possible design, incorporating the vent 14 acting as a nose. [0035] Additional embodiments of the invention have a section that is heat sealed onto the surface of the ball, creating an off weighted ball, giving a crazy wobble effect. The heat sealed section of these embodiments can be located either on the inside or outside surface of the ball. Figure 8 shows an example of this type of embodiment. The outer casing 10 of the ball has an extra section 42 heat sealed to the outer surface. This extra section 42 will cause the ball to move in a wobbly manner. The extra section can have an inflation tube like that shown in Figure 7, or can be inflated from within the inside of the ball during inflation of the ball. In other embodiments, the extra section 42 can be located on the internal surface of the ball, hidden from view. [0036] While there have been shown, described and pointed out fundamental novel features of the invention as applied to preferred embodiments and aspects thereof, it will be understood that various omissions and substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art without departing from the spirit of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto.