TWI651117B - 球體結構及其製造方法 - Google Patents

球體結構及其製造方法 Download PDF

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Publication number
TWI651117B
TWI651117B TW106141088A TW106141088A TWI651117B TW I651117 B TWI651117 B TW I651117B TW 106141088 A TW106141088 A TW 106141088A TW 106141088 A TW106141088 A TW 106141088A TW I651117 B TWI651117 B TW I651117B
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TW
Taiwan
Prior art keywords
layer
polyurethane
solution
ball
bladder
Prior art date
Application number
TW106141088A
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English (en)
Other versions
TW201924754A (zh
Inventor
馮崇智
吳俊偉
林永松
Original Assignee
三芳化學工業股份有限公司
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Priority to TW106141088A priority Critical patent/TWI651117B/zh
Priority to DE102018123732.4A priority patent/DE102018123732A1/de
Priority to US16/149,528 priority patent/US10357691B2/en
Application granted granted Critical
Publication of TWI651117B publication Critical patent/TWI651117B/zh
Publication of TW201924754A publication Critical patent/TW201924754A/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D22/00—Producing hollow articles
    • B29D22/02—Inflatable articles
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
    • A63B41/00—Hollow inflatable balls
    • A63B41/08—Ball covers; Closures therefor
    • A—HUMAN NECESSITIES
    • A63—SPORTS; GAMES; AMUSEMENTS
    • A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
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    • A63B41/02—Bladders
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    • A63B45/00—Apparatus or methods for manufacturing balls
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

本發明係關於一種球體結構及其製造方法。該球體結構包括一球膽及複數個球皮。該等球皮環繞該球膽，每一球皮包括一基布層、一中間層及一面層。該中間層係由一第一聚氨酯溶液所形成，該第一聚氨酯溶液之聚氨酯固形份係高於70重量百分比，該中間層係為一發泡層，其空孔率為25%至85%。該面層係由一第二聚氨酯溶液所形成，該第二聚氨酯溶液之聚氨酯固形份係為5重量百分比至20重量百分比。

Description

球體結構及其製造方法
本發明係關於一種球體結構及其製造方法，特別是一種球皮不需貼合乙烯-醋酸乙烯共聚合物(EVA)之球體結構及其製造方法。
參考圖1，顯示習知足球9之立體示意圖。參考圖2，顯示圖1之習知足球9之局部剖視示意圖。該習知足球9包括一球膽(Inner Bladder)90、一中胎(Middle Bladder)92、一乙烯-醋酸乙烯共聚合物(EVA)層94及複數個球皮(Cover)96。該球膽90係可充氣而形成一球形結構，其材質通常為橡膠。該中胎92包覆該球膽90。該中胎92之材質通常為帆布，其係裁成複數個五邊形片材後縫製而成一球形。該乙烯-醋酸乙烯共聚合物(EVA)層94係貼合於該中胎92上。該等球皮96之材質通常為真皮、橡膠或人工皮革，其通常為24片。該等球皮96係貼合於該中胎92上。 參考圖3，顯示習知足球9之製造方法之示意圖。該習知足球9之製造方法如下所述。首先，將用於該中胎92之帆布材質裁成複數個五邊形片材後縫製而成一球形。接著，將該球膽90置放於該中胎92內。接著，形成該乙烯-醋酸乙烯共聚合物(EVA)層94於該中胎92之表面上。接著，將該等球皮96貼合於該乙烯-醋酸乙烯共聚合物(EVA)層94上，以製得圖1及圖2所示之習知足球9。 該習知足球9之製造方法中，用於該中胎92之帆布之裁切必須以人工去進行，因此其缺點有加工時間長、人力成本高、生產效率較低及產品穩定性差等。此外，該乙烯-醋酸乙烯共聚合物(EVA)層94並不環保，容易造成環境污染。 因此，有必要提供一創新且富進步性的球體結構及其製造方法，以解決上述問題。
本發明係提供一種球體結構，其包括一球膽及複數個球皮。該等球皮環繞該球膽，每一球皮包括一基布層、一中間層及一面層。該基布層之厚度為約0.5mm至3mm。該中間層係由一第一聚氨酯(Polyurethane, PU)溶液所形成，該第一聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係高於70重量百分比（wt%），該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%。該面層係由一第二聚氨酯(Polyurethane, PU)溶液所形成，該第二聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係為5重量百分比（wt%）至20重量百分比（wt%），該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm。 本發明另提供一種球體結構之製造方法，其包括以下步驟：(a)提供一球膽及一中胎，其中該中胎包覆該球膽；(b)提供複數個球皮，其中每一球皮包括一基布層、一中間層及一面層，該基布層之厚度為約0.5mm至3mm，該中間層係由一第一聚氨酯(Polyurethane, PU)溶液所形成，該第一聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係高於70重量百分比（wt%），該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%，該面層係由一第二聚氨酯(Polyurethane, PU)溶液所形成，該第二聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係為5重量百分比（wt%）至20重量百分比（wt%），該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm；及(c)將該等球皮之基布層貼合於該中胎上。 本發明另提供一種球體結構之製造方法，包括以下步驟：(a)提供複數個球皮，其中每一球皮包括一基布層、一中間層及一面層，該基布層之厚度為約0.5mm至3mm，該中間層係由一第一聚氨酯(Polyurethane, PU)溶液所形成，該第一聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係高於70重量百分比（wt%），該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%，該面層係由一第二聚氨酯(Polyurethane, PU)溶液所形成，該第二聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係為5重量百分比（wt%）至20重量百分比（wt%），該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm，其中該面層具有一第一表面遠離該基布層；(b)接合複數個相鄰球皮之外週邊緣之面層之第一表面，以形成一外表皮結構；(c)將該外表皮結構由內向外翻面，使得該面層之第一表面朝外，該外表皮結構形成大致為一球體之結構，且具有一缺口；(d)經由該缺口置放一球膽於該外表皮結構內；及(e)附著至少一球皮於被該缺口所顯露之該球膽上。
參考圖4至圖7，顯示本發明積層材1之製造方法之一實施例之製程步驟示意圖。參考圖4，利用塗佈方式形成一第二聚氨酯(Polyurethane, PU)溶液於一離型紙10上，該第二聚氨酯(Polyurethane, PU)溶液於30℃之黏度為1200 cps至1800 cps。該第二聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係為5重量百分比（wt%）至20重量百分比（wt%），較佳為10重量百分比（wt%）至15重量百分比（wt%）。接著，於100℃至120℃溫度下烘乾第二聚氨酯(Polyurethane, PU)溶液2分鐘，以形成一面層12。在本實施例中，該面層12之厚度為約0.02mm至0.2mm。 參考圖5，利用塗佈方式形成一第一聚氨酯(Polyurethane, PU)溶液於該面層12上，該第一聚氨酯(Polyurethane, PU)溶液於30℃之黏度為10000 cps至30000 cps。該第一聚氨酯(Polyurethane, PU)溶液之聚氨酯固形份係高於70重量百分比（wt%），較佳為80重量百分比（wt%）以上。在一實施例中，該第一聚氨酯(Polyurethane, PU)溶液可更包含界面劑、硬化劑、發泡劑及色料。在本實施例中，該第一聚氨酯(Polyurethane, PU)溶液係包含83重量百分比（wt%）之聚氨酯樹脂、0.5重量百分比（wt%）至1重量百分比（wt%）之界面劑、4重量百分比（wt%）至6重量百分比（wt%）之硬化劑、2重量百分比（wt%）至5重量百分比（wt%）之發泡劑及2重量百分比（wt%）至5重量百分比（wt%）之色料。此外，該第一聚氨酯(Polyurethane, PU)溶液在塗佈於該面層12之前可經攪拌後作真空脫泡處理以去除攪拌過程中的空氣，之後才塗佈於該面層12上。接著，於150℃至170℃溫度下烘乾第一聚氨酯(Polyurethane, PU)溶液2分半至3分鐘，以形成一中間層14。在本實施例中，該中間層14係為發泡層，其空孔率為25%至85%，較佳為50%至60%；其硬度（ASK C）為25至50。該中間層14之厚度為約2mm至5mm，較佳為約3mm至5mm。 參考圖6，利用塗佈方式形成一膠合層溶液於該中間層14上。在本實施例中，該膠合層溶液之材質係為聚氨酯(Polyurethane, PU)溶液，且其聚氨酯固形份係為約50重量百分比（wt%）。 參考圖7，將一基布層18壓合且黏附於該膠合層溶液上。該基布層18係為一布料，例如：織布、超纖布或不織布。在本實施例中，該基布層18之厚度為約0.5mm至3mm。接著，於60℃至140℃溫度下烘乾該膠合層溶液，以形成一膠合層16。接著，移除該離型紙10，以得該積層材1。 參考圖8，顯示本發明中球皮20之一實施例之立體示意圖。參考圖9，顯示圖8之球皮20之局部剖視示意圖。該球皮20係由該積層材1（圖7）裁切而成，用以做為一球體結構之最外表面。該球皮20包括該基布層18、該膠合層16、該中間層14及該面層12。該中間層14係經由該膠合層16黏附於該基布層18。該中間層14係位於該面層12與該基布層18之間。該面層12具有一第一表面121。該第一表面121係為該球皮20之上表面，且遠離該基布層18。該球皮20具有一側面22。 參考圖10，顯示本發明中球皮21之一實施例之立體示意圖。在本實施例中，利用高周波或其他方式加壓於該球皮21之上表面，使得該面層12之第一表面121具有一凹陷圖案。 參考圖11，顯示本發明球體結構3之一實施例之立體示意圖。參考圖12，顯示圖11之球體結構3之局部剖視示意圖。在本實施例中，該球體結構3係為一足球。該球體結構3包括一球膽(Inner Bladder)30、一中胎(Middle Bladder)32及複數個球皮(Cover)20。該球膽30係可充氣而形成一球形結構，其材質可以是橡膠。該中胎32包覆該球膽30。該中胎32材質可以是橡膠或帆布。該等球皮20係為圖8及圖9或圖10所示之球皮20，其通常為8片、16片或24片。該等球皮20之基布層18係貼合於該中胎32上。亦即，該等球皮20環繞該球膽30。 較佳地，相鄰球皮20之側面22彼此面對或彼此接合。要注意的是，該球體結構3之製程並不需要形成該乙烯-醋酸乙烯共聚合物(EVA)層，因此較為環保，不易造成環境污染。 參考圖13，顯示本發明球體結構3之製造方法之一實施例之示意圖。該球體結構3之製造方法如下所述。首先，提供該球膽30及該中胎32，其中該中胎32包覆該球膽30。在本實施例中，該中胎32之材質係為帆布，其係裁成複數個五邊形片材後縫製而成一球形。接著，再將該球膽30塞入該中胎32中。在另一實施例中，將該球膽30置放於一模具中（圖中未示）後，形成該中胎32（該中胎32之材質係為橡膠）於該球膽30外表面。 接著，提供該等球皮20，其中該等球皮20係為圖8及圖9或圖10所示之球皮20。接著，將該等球皮20之基布層18以高周波或其他方式貼合或接著於該中胎32上，以製得如圖11及圖12之球體結構3。 在本實施例中，該等球皮20係直接貼合或壓合於該中胎32上，而不需形成該乙烯-醋酸乙烯共聚合物(EVA)層，因而可降低加工時間及成本，且較為環保。此外，該球體結構3之製造方法之優點有加工時間短、人力成本低、生產效率較高及產品穩定性佳等。 參考圖14，顯示本發明球體結構5之一實施例之立體示意圖。參考圖15，顯示圖14之球體結構5之第一部分之局部剖視示意圖。參考圖16，顯示圖14之球體結構5之第二部分之局部剖視示意圖。在本實施例中，該球體結構5係為一足球。該球體結構5包括一球膽(Inner Bladder)30及複數個球皮(Cover)20。該球膽30係可充氣而形成一球形結構，其材質可以是橡膠。該等球皮20係環繞該球膽30。相鄰球皮20之面層12之第一表面121於該等球皮20之外週邊緣彼此接合而形成一接合面52，該接合面52大致垂直於該球膽30之外表面。亦即，在本實施例中，可省略該中胎32。在本實施例中，該等球皮20之下表面可以不接合或附著至該球膽30。亦即，該等球皮20之該基布層18與該球膽30外表面間可以具有一間隙。 如圖16所示，該球體結構5更具有至少一球皮20a，該球皮20a之結構與該等球皮20相同，然而，該球皮20a係直接附著或貼合於該球膽30上（該球皮20a可視為一密封球皮）。亦即，該球皮20a與該等球皮20並未形成該接合面52，且該球皮20a之側面係面對或接觸該等球皮20之側面22。 要注意的是，該球體結構5之製程並不需要形成該乙烯-醋酸乙烯共聚合物(EVA)層，因而可降低加工時間及成本，且較為環保。 參考圖17，顯示本發明球體結構5a之一實施例之第一部分之局部剖視示意圖。參考圖18，顯示圖17之球體結構5a之第二部分之局部剖視示意圖。本實施例之球體結構5a與圖14至圖16之球體結構5大致相同，其不同處僅在於本實施例之該球體結構5a更包括該中胎32，位於該球膽30與該等球皮20, 20a之間。因此，該等球皮20係環繞該中胎32。此外，如圖18所示，該球皮20a係直接附著或貼合於該中胎32上。 參考圖19至圖22，顯示本發明球體結構5之製造方法之一實施例之示意圖。該球體結構5之製造方法如下所述。首先，參考圖19，提供複數個球皮20。該等球皮20係為圖8及圖9或圖10所示之球皮20，其中每一球皮20包括一基布層18、一膠合層16、一中間層14及一面層12。該中間層14係經由該膠合層16黏附於該基布層18。該中間層14係位於該面層12與該基布層18之間。該面層12具有一第一表面121。該第一表面121係為該球皮20之上表面，且遠離該基布層18。該球皮20具有一側面22。接著，將二個球皮20以第一表面121面對第一表面121方式排列。接著，接合（例如：以高周波方式）二個相鄰球皮20之外週邊緣之面層12之第一表面121之一部分，以形成一接合面52。 參考圖20，以同樣上述方式接合其他複數個預先規劃好之相鄰球皮20，以形成一外表皮結構6。此時，該面層12之第一表面121係位於該外表皮結構6之內側，而該基布層18係位於該外表皮結構6之外側。 參考圖21，將該外表皮結構6由內向外翻面，使得該面層12之第一表面121朝外，且該基布層18係位於該外表皮結構6之內側。此時，該外表皮結構6形成大致為一球體之結構，且具有一缺口62。該缺口62之尺寸與至少一球皮20a（圖22）大致相同。接著，將未充氣之該球膽30經由該缺口62置放於該外表皮結構6內。 參考圖22，將該球膽30充氣後，再將至少一球皮20a附著（例如：貼附）於被該缺口62所顯露之該球膽30上，以製得如圖14至圖16所示之球體結構5。在其他實施例中，在圖21所置放之該球膽30更包覆一中胎32，則在圖22中該至少一球皮20a係附著於被該缺口62所顯露之該中胎32上，以製得如圖17至圖18所示之球體結構5a。 在本實施例中，該等球皮20係直接互相接合而形成該外表皮結構6，而不需形成該乙烯-醋酸乙烯共聚合物(EVA)層，因而可降低加工時間及成本，且較為環保。此外，該球體結構5, 5a之製造方法之優點有加工時間短、人力成本低、生產效率較高及產品穩定性佳等。 上述實施例僅為說明本發明之原理及其功效，而非限制本發明。本發明所屬技術領域中具通常知識者對上述實施例所做之修改及變化仍不違背本發明之精神。本發明之權利範圍應如後述之申請專利範圍所列。
1‧‧‧本發明積層材
3‧‧‧本發明球體結構
5‧‧‧本發明球體結構
5a‧‧‧本發明球體結構
6‧‧‧外表皮結構
9‧‧‧習知足球
10‧‧‧離型紙
12‧‧‧面層
14‧‧‧中間層
16‧‧‧膠合層
18‧‧‧基布層
20‧‧‧球皮
20a‧‧‧球皮
21‧‧‧球皮
22‧‧‧側面
30‧‧‧球膽
32‧‧‧中胎
52‧‧‧接合面
62‧‧‧缺口
90‧‧‧球膽
92‧‧‧中胎
94‧‧‧乙烯-醋酸乙烯共聚合物(EVA)層
96‧‧‧球皮
121‧‧‧第一表面
圖1顯示習知足球之立體示意圖。 圖2顯示圖1之習知足球之局部剖視示意圖。 圖3顯示習知足球之製造方法之示意圖。 圖4至圖7顯示本發明積層材之製造方法之一實施例之製程步驟示意圖。 圖8顯示本發明中球皮之一實施例之立體示意圖。 圖9顯示圖8之球皮之局部剖視示意圖。 圖10顯示本發明中球皮之一實施例之立體示意圖。 圖11顯示本發明球體結構之一實施例之立體示意圖。 圖12顯示圖11之球體結構之局部剖視示意圖。 圖13顯示本發明球體結構之製造方法之一實施例之示意圖。 圖14顯示本發明球體結構之一實施例之立體示意圖。 圖15顯示圖14之球體結構之第一部分之局部剖視示意圖。 圖16顯示圖14之球體結構之第二部分之局部剖視示意圖。 圖17顯示本發明球體結構之一實施例之第一部分之局部剖視示意圖。 圖18顯示圖17之球體結構之第二部分之局部剖視示意圖。 圖19至圖22顯示本發明球體結構之製造方法之一實施例之示意圖。

Claims (10)

  1. 一種球體結構，包括：一球膽；及複數個球皮，環繞該球膽，每一球皮包括：一基布層，其厚度為約0.5mm至3mm；一中間層，係由一第一聚氨酯(Polyurethane,PU)溶液所形成，該第一聚氨酯溶液於30℃之黏度為10000cps至30000cps，該第一聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係高於70重量百分比(wt%)，該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%；及一面層，係由一第二聚氨酯(Polyurethane,PU)溶液所形成，該第二聚氨酯溶液於30℃之黏度為1200cps至1800cps，該第二聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係為5重量百分比(wt%)至20重量百分比(wt%)，該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm。
  2. 如請求項1之球體結構，更包括一中胎，該中胎之材質係為橡膠或帆布，該中胎包覆該球膽，且該等球皮之基布層貼合於該中胎上，使得該等球皮環繞該球膽。
  3. 如請求項1之球體結構，其中每一球皮之面層具有一第一表面遠離該基布層，相鄰球皮之面層之第一表面於該等球皮之外週邊緣彼此接觸接合。
  4. 如請求項3之球體結構，其中至少一球皮係附著於該球膽上。
  5. 如請求項1之球體結構，其中每一球皮更包括一膠合層，該中間層係利用該膠合層黏附於該基布層。
  6. 一種球體結構之製造方法，包括以下步驟：(a)提供一球膽及一中胎，其中該中胎包覆該球膽；(b)提供複數個球皮，其中每一球皮包括一基布層、一中間層及一面層，該基布層之厚度為約0.5mm至3mm，該中間層係由一第一聚氨酯(Polyurethane,PU)溶液所形成，該第一聚氨酯溶液於30℃之黏度為10000cps至30000cps，該第一聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係高於70重量百分比(wt%)，該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%，該面層係由一第二聚氨酯(Polyurethane,PU)溶液所形成，該第二聚氨酯溶液於30℃之黏度為1200cps至1800cps，該第二聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係為5重量百分比(wt%)至20重量百分比(wt%)，該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm；及(c)將該等球皮之基布層貼合於該中胎上。
  7. 如請求項6之製造方法，其中該步驟(b)中，每一球皮更包括一膠合層，該中間層係利用該膠合層黏附於該基布層。
  8. 一種球體結構之製造方法，包括以下步驟：(a)提供複數個球皮，其中每一球皮包括一基布層、一中間層及一面層，該基布層之厚度為約0.5mm至3mm，該中間層係由一第一聚氨酯(Polyurethane,PU)溶液所形成，該第一聚氨酯溶液於30℃之黏度為10000cps至30000cps，該第一聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係高於70重量百分比(wt%)，該中間層之厚度為約2mm至5mm，該中間層係為一發泡層，其空孔率為25%至85%，該面層係由一第二聚氨酯(Polyurethane,PU)溶液所形成，該第二聚氨酯溶液於30℃之黏度為1200cps至1800cps，該第二聚氨酯(Polyurethane,PU)溶液之聚氨酯固形份係為5重量百分比(wt%)至20重量百分比(wt%)，該中間層係位於該面層與該基布層之間，該面層之厚度為約0.02mm至0.2mm，其中該面層具有一第一表面遠離該基布層；(b)接合複數個相鄰球皮之外週邊緣之面層之第一表面，以形成一外表皮結構；(c)將該外表皮結構由內向外翻面，使得該面層之第一表面朝外，該外表皮結構形成大致為一球體之結構，且具有一缺口；(d)經由該缺口置放一球膽於該外表皮結構內；及(e)附著至少一球皮於被該缺口所顯露之該球膽上。
  9. 如請求項8之製造方法，其中該步驟(a)中，每一球皮更包括一膠合層，該中間層係利用該膠合層黏附於該基布層。
  10. 如請求項8之製造方法，其中該步驟(b)之接合方式係利用高周波接合。
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