Methods of manufacturing of tri-tech soccer ball

A manufacturing method of a soccer ball, comprising the steps of:

• preparing a composite multilayer sheet consisting a plurality of layers including at least an outer layer of leather or bi-cast leather or plastics or polyvinyl chloride fixed with a foamy substance of Ethylene Propylene Diene Monomer (EPDM) rubber or non EPDM foam of homogenous density and of size up to 10 mm by an adhesive;
• adjoining one or more additional layer(s) of rubber or synthetic rubber or fabric to bi-cast leather by applying a layer of adhesive material on upper and lowers sides of the additional layer(s);
• applying of a layer of adhesive to at least a bi-cast leather or additional layer to fix to the foamy substance;
• cutting out of panel cut-outs and bladder valve panel cut-out of specific sizes and shapes from the composite multilayer sheet;
• determining of assembling zone area of up to 10 mm from the edges of the panel cut-outs for each of the plurality of the panel cut-outs which encircles central part of the foamy substance;
• strengthening of the assembling zone by applying tape-like support strips of fabric or rubber are selectively applied to the assembling zones on the outer portion but inner side of the panel cut-outs;
• selective partial cutting of the panel cut-outs from 2 mm to 6 mm deep and at 4 mm to 10 mm from the panel cut-out's edge near the edge of the support strip so the central part of the foamy substance is partially cut from the assembling zone, to release pressure of the seams, edges and fabric of the panel cut-outs on the foamy substance in the central portion of the panel cut-outs;
• applying high pressure and high frequency waves to the assembling zone to further enhance the ‘popping-up’ to create a ‘punched-out’ effect of the central part of the foamy substance which creates selective changes in the density of the assembling zone;
• making the maximum thickness of each of the plurality of the panel cut-outs is 6 to 9 mm and the assembling zone thickness at the seam lines is 2 mm to 3 mm;
• applying a layer of adhesive to the outer side of the assembling zone to adjoining two contiguous aforesaid panel cut-outs to enhances the attachment, making it the water resistant, hiding the stitches;
• and for the stability of probable size change of the soccer ball;
• attaching a bladder with the bladder valve panel cut-out which is one of the plurality of the panel cut-outs;
• and is specially prepared by adjoining combination of leather and the support strip to the foamy substance;
• stitching of the plurality of the panel cut-outs including the bladder valve panel cut-out by using machine stitching at the assembling zones;
• and inside inversion of the soccer ball formed by this stitching of the plurality of the panel cut-outs;
• Stitching by hand for remaining unstitched stitch-lines of the panel cut-outs of the soccer ball;
• and
• Insertion of air at a high pressure in the soccer ball while placing in a non-expandable hot mold wherein molding the soccer ball in a non-expandable mold until popped-up foamy substance created by selective strengthening of the assembling zone and release of pressure on the central part of foamy substance by the selective partial cutting of the foamy substance fills up the space between outer layer of aforesaid stitched panel cut-outs and bladder created by the in-turning of the edges during stitching.