TWI754267B - 熱塑性聚氨酯球結構及其製造方法 - Google Patents
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Abstract
本發明係關於一種熱塑性聚氨酯球結構及其製造方法。該熱塑性聚氨酯球結構包括:一球內膽層、一紗線層及一表皮層。該球內膽層以熱塑性聚氨酯材料製作。該紗線層以熱塑性聚氨酯材料製作,該紗線層包覆該球內膽層。該表皮層以熱塑性聚氨酯材料製作,該表皮層包覆該紗線層。本發明之熱塑性聚氨酯球結構係全部使用熱塑性聚氨酯材料製成,符合環保需求並可回收。並且,不需要利用黏著劑黏合各層,可提升各層間之剝離強度,並使得本發明之熱塑性聚氨酯球結構之整體剝離強度提升。
Description
本發明關於一種熱塑性聚氨酯球結構及其製造方法。
習知足球結構係以橡膠內膽、尼龍(Nylon)長纖維、乙烯-醋酸乙烯共聚合物(EVA)泡棉等材料製作,然而習知製作足球製程中需使用溶劑,該溶劑會危害環境,不符合環保需求。並且,習知製作足球製程中需使用黏著劑黏合各層,且由於各層之材料不同,其各層間之剝離強度不佳,使得習知足球結構之整體剝離強度不足。
因此,有必要提供一創新且具進步性之熱塑性聚氨酯球結構及其製造方法,以解決上述習知缺失。
本發明係關於一種熱塑性聚氨酯球結構。在一實施例中,該熱塑性聚氨酯球結構包括:一球內膽層、一紗線層及一表皮層。該球內膽層以熱塑性聚氨酯材料製作。該紗線層以熱塑性聚氨酯材料製作,該紗線層包覆該球內膽層。該表皮層以熱塑性聚氨酯材料製作,該表皮層包覆該紗線層。
本發明係關於一種熱塑性聚氨酯球結構之製造方法。在一實施例中,該熱塑性聚氨酯球結構之製造方法包括以下步驟:製作一球內膽層,其係以熱塑性聚氨酯材料製作;以熱塑性聚氨酯紗包覆該球內膽層,以形成一紗線層;製作一表皮層,其係以熱塑性聚氨酯材料製作;及將該
表皮層包覆該紗線層,並熱加工處理。
10:熱塑性聚氨酯球結構
11:球內膽層
12:紗線層
13:表皮層
111:第一高回彈熱塑性聚氨酯層
112:高氣密熱塑性聚氨酯層
113:第二高回彈熱塑性聚氨酯層
131:外皮層
132:發泡乳膠層
133:未發泡乳膠層
S41~S44:步驟
圖1顯示本發明一實施例熱塑性聚氨酯球結構之示意圖。
圖2顯示本發明一實施例球內膽層之結構示意圖。
圖3顯示本發明一實施例表皮層之結構示意圖。
圖4顯示本發明一實施例熱塑性聚氨酯球結構之製造方法流程示意圖。
參閱圖1,其係顯示本發明一實施例熱塑性聚氨酯球結構之結構示意圖。在一實施例中,本發明之熱塑性聚氨酯球結構10包括:一球內膽層11、一紗線層12及一表皮層13。該球內膽層11以熱塑性聚氨酯(TPU)材料製作。該紗線層12以熱塑性聚氨酯(TPU)材料製作,該紗線層12包覆該球內膽層11。該表皮層13以熱塑性聚氨酯(TPU)材料製作,該表皮層13包覆該紗線層12。本發明之熱塑性聚氨酯球結構10可應用於各式球類,例如足球等,但不以上述為限。
在一實施例中,該球內膽層11係以熱塑性聚氨酯長纖維纏繞,以一球內膽製程製作。參閱圖2,其係顯示本發明一實施例球內膽層之結構示意圖。在一實施例中,該球內膽層11包括一第一高回彈熱塑性聚氨酯層111、一高氣密熱塑性聚氨酯層112及一第二高回彈熱塑性聚氨酯層113。該高氣密熱塑性聚氨酯層112設置於第二高回彈熱塑性聚氨酯層113上,且該第一高回彈熱塑性聚氨酯層111設置於該高氣密熱塑性聚氨酯層112上。該第一高回彈熱塑性聚氨酯層111、該高氣密熱塑性聚氨酯層112及該第二高回彈熱塑性聚氨酯層113之厚度複合比為1:2:1。在一實施例
中,該第一高回彈熱塑性聚氨酯層之厚度可為0.05mm,該高氣密熱塑性聚氨酯層之厚度可為0.1mm,該第二高回彈熱塑性聚氨酯層之厚度可為0.05mm。
在一實施例中,該紗線層12係以熱塑性聚氨酯纏繞紗或熱塑性聚氨酯熱熔紗製成。該熱塑性聚氨酯纏繞紗或熱塑性聚氨酯熱熔紗可為熱塑性聚氨酯彈性體。該紗線層12可經熱加工處理,熔融黏合該球內膽層11及該表皮層13。
參閱圖3,其係顯示本發明一實施例表皮層之結構示意圖。在一實施例中,該表皮層13包括一外皮層131及一乳膠層。該乳膠層包括一發泡乳膠層132及一未發泡乳膠層133,該發泡乳膠層132設置於該未發泡乳膠層133上,該外皮層131設置於該發泡乳膠層132上。該外皮層131、該發泡乳膠層132及該未發泡乳膠層133之厚度複合比為1:8:1。在一實施例中,該外皮層131之厚度為0.1-0.3mm,該發泡乳膠層132之厚度為0.4-1.6mm,該未發泡乳膠層133之厚度為0.1-0.3mm。在一實施例中,該外皮層131之厚度可為0.2mm,該發泡乳膠層132之厚度可為1.6mm,該未發泡乳膠層133之厚度可為0.2mm。
本發明之熱塑性聚氨酯球結構10係全部使用熱塑性聚氨酯材料製成,符合環保需求並可回收,且不需使用任何溶劑,不會危害環境。並且,本發明之熱塑性聚氨酯球結構10之各層均以相同的熱塑性聚氨酯材料製作,且不需要利用黏著劑黏合各層,本發明之熱塑性聚氨酯球結構10可利用熔融黏合各層,可提升各層間之剝離強度,並使得本發明之熱塑性聚氨酯球結構10之整體剝離強度提升。
參閱圖4,其係顯示本發明一實施例熱塑性聚氨酯球結構之
製造方法流程示意圖。請配合參考圖1及圖4,首先參考步驟S41,製作該球內膽層11,其係以熱塑性聚氨酯材料製作。在一實施例中,在製作該球內膽層之步驟中,包括:準備黏度為0.5~2的熱塑性聚氨酯酯粒,並經過一乾燥筒乾燥,使熱塑性聚氨酯酯粒的含水率在20~50ppm間,再使用一熔紡製程,將乾燥後的熱塑性聚氨酯酯粒輸送至一押出機內,熔融後輸送到一計量泵,經該計量泵輸送到一紡絲組件,以噴出熱塑性聚氨酯絲,再經過風溫為10~50℃的冷卻風冷卻後,再以一延伸羅拉裝置(Drawing rollers)進行延伸,再使用一卷繞機(Winder)進行卷繞,以製得200~500 den熱塑性聚氨酯長纖維,再經一球內膽製程,以製得該球內膽層11。
在一實施例中,該熱塑性聚氨酯長纖維之物性為5~15g/d,其10%初始強度為0.5~1.5kgf,其伸長率為5~30%。
請配合參考圖1、圖2及圖4,在一實施例中,在製作該球內膽層11之步驟中,包括:製作一第一高回彈熱塑性聚氨酯層111、一高氣密熱塑性聚氨酯層112及一第二高回彈熱塑性聚氨酯層113之步驟,其中以一第一乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第一押出機熔融該熱塑性聚氨酯酯粒,該第一押出機之熔融溫度為160℃-180℃,在一實施例中,該第一押出機之熔融溫度設定依序為160℃、180℃、175℃。DIE溫度為180℃,經一第一計量泵,以製作該第一高回彈熱塑性聚氨酯層111。
在一實施例中,以一第二乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第二押出機熔融該熱塑性聚氨酯酯粒,該第二押出機之熔融溫度為160℃-190℃,在一實施例中,該第
二押出機之熔融溫度設定依序為160℃、190℃、180℃。DIE溫度為180℃,經一第二計量泵,以製作該高氣密熱塑性聚氨酯層112。
在一實施例中,以一第三乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第三押出機熔融該熱塑性聚氨酯酯粒,該第三押出機之熔融溫度為160℃-180℃,在一實施例中,該第三押出機之熔融溫度設定依序為160℃、180℃、175℃。DIE溫度為180℃,經一第三計量泵,以製作該第二高回彈熱塑性聚氨酯層113。
利用一第一淋膜輪冷卻成膜使該高氣密熱塑性聚氨酯層112設置於第二高回彈熱塑性聚氨酯層113上,該第一高回彈熱塑性聚氨酯層111設置於該高氣密熱塑性聚氨酯層112上。該第一高回彈熱塑性聚氨酯層111、該高氣密熱塑性聚氨酯層112及該第二高回彈熱塑性聚氨酯層113之厚度複合比為1:2:1。在一實施例中,該第一淋膜輪的速度為4.0m/min,以製作得總厚度為0.2mm的該球內膽層11,該第一高回彈熱塑性聚氨酯層111之厚度可為0.05mm,該高氣密熱塑性聚氨酯層112之厚度可為0.1mm,該第二高回彈熱塑性聚氨酯層113之厚度可為0.05mm。其測試數據如下所示:
請配合參考圖1及圖4,參考步驟S42,以熱塑性聚氨酯紗包覆該球內膽層11,以形成一紗線層12。在一實施例中,該熱塑性聚氨酯紗係纏繞包覆該球內膽層11,以形成該紗線層12。請參考以下於10%伸長率時的斷裂強度比較圖,其顯示習知的尼龍(NYLON 66220D)紗線與本發明熱塑性聚氨酯紗(HT-F 210D)之比較,明顯地,本發明熱塑
性聚氨酯紗(HT-F 210D)於各次拉力測試之斷裂強度皆高於習知的尼龍(NYLON 66220D)紗線。且每次斷裂強度較為平均。
請配合參考圖1、圖3及圖4,參考步驟S43,製作一表皮層13,其係以熱塑性聚氨酯材料製作。在一實施例中,在製作該表皮層13之步驟中,包括:製作一外皮層131、一發泡乳膠層132及一未發泡乳膠層133之步驟,其中使用蕭式硬度80~90A、熔點140~160℃的熱塑性聚氨酯粒子,以一第四乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下。並利用一第四押出機熔融該熱塑性聚氨酯酯粒,該第四押出機之熔融溫度為185℃-200℃,在一實施例中,該第四押出機之熔融溫度設定依序為185℃、200℃、195℃。DIE溫度為185℃,經一第四計量泵,以製作該外皮層131。
在一實施例中,使用蕭式硬度60~85A、熔點120~140℃的熱塑性聚氨酯粒子,以一第五乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下。並利用一第五押出機熔融該熱塑性聚氨酯酯粒,且添加微球發泡劑0.5-5.0%,該第五押出機之熔融溫度為160℃-190℃,在一實施例中,該第五押出機之熔融溫度設定依序為160℃、190℃、185℃。DIE溫度為185℃,經一第五計量泵,以製作該發泡乳膠層132。
在一實施例中,使用蕭式硬度60~85A、熔點90~130℃的熱
塑性聚氨酯粒子,以一第六乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第六押出機熔融該熱塑性聚氨酯酯粒,該第六押出機之熔融溫度為160℃-180℃,在一實施例中,該第六押出機之熔融溫度設定依序為160℃、180℃、170℃。DIE溫度為185℃,經一第六計量泵,以製作該未發泡乳膠層133。
在一實施例中,利用一第二淋膜輪冷卻成膜使該發泡乳膠層132設置於該未發泡乳膠層133上,該外皮層131設置於該發泡乳膠層132上。該外皮層、該發泡乳膠層及該未發泡乳膠層之厚度複合比為1:8:1。在一實施例中,該第二淋膜輪的速度為4.0m/min,以製作得總厚度為2.0mm的該表皮層13,該外皮層131之厚度可為0.2mm,該發泡乳膠層132之厚度可為1.6mm,該未發泡乳膠層133之厚度可為0.2mm。在一實施例中,該外皮層131之厚度為0.1-0.3mm,該發泡乳膠層132之厚度為0.4-1.6mm,該未發泡乳膠層133之厚度為0.1-0.3mm。
請配合參考圖1及圖4,參考步驟S44,將該表皮層13包覆該紗線層12,並熱加工處理。在一實施例中,利用熱加工處理,該紗線層12可熔融黏合該球內膽層11及該表皮層13。
在一實施例中,本發明之製造方法另包括一壓制轉寫紋路之步驟,係利用一冷卻輪(Cold mold),將紋路轉寫至該外皮層131。
本發明熱塑性聚氨酯球結構10之製造方法係全部使用熱塑性聚氨酯材料製成,符合環保需求並可回收,且上述製造方法不需使用任何溶劑,不會危害環境。並且,本發明之熱塑性聚氨酯球結構10之各層均以相同的熱塑性聚氨酯材料製作,不需要利用黏著劑黏合各層,本發明熱塑性聚氨酯球結構10之製造方法以熔融黏合各層,可提升各層間
之剝離強度,並使得本發明之熱塑性聚氨酯球結構10之整體剝離強度提升。
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。習於此技術之人士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。
10:熱塑性聚氨酯球結構
11:球內膽層
12:紗線層
13:表皮層
Claims (7)
- 一種熱塑性聚氨酯球結構,包括:一球內膽層,以熱塑性聚氨酯材料製作;一紗線層,以熱塑性聚氨酯材料製作,該紗線層包覆該球內膽層;及一表皮層,以熱塑性聚氨酯材料製作,該表皮層包覆該紗線層;其中該表皮層包括一外皮層及一乳膠層,該乳膠層包括一發泡乳膠層及一未發泡乳膠層,該發泡乳膠層設置於該未發泡乳膠層上,該外皮層設置於該發泡乳膠層上,該外皮層、該發泡乳膠層及該未發泡乳膠層之厚度複合比1:8:1,且該外皮層之厚度為0.1-0.3mm,該發泡乳膠層之厚度為0.4-1.6mm,該未發泡乳膠層之厚度為0.1-0.3mm。
- 如請求項1之熱塑性聚氨酯球結構,其中該紗線層纏繞包覆該球內膽層。
- 如請求項1之熱塑性聚氨酯球結構,其中該紗線層係以熱塑性聚氨酯纏繞紗或熱塑性聚氨酯熱熔紗製成。
- 一種熱塑性聚氨酯球結構,包括:一球內膽層,以熱塑性聚氨酯材料製作;一紗線層,以熱塑性聚氨酯材料製作,該紗線層包覆該球內膽 層;及一表皮層,以熱塑性聚氨酯材料製作,該表皮層包覆該紗線層;其中該球內膽層包括一第一高回彈熱塑性聚氨酯層、一高氣密熱塑性聚氨酯層及一第二高回彈熱塑性聚氨酯層,該高氣密熱塑性聚氨酯層設置於第二高回彈熱塑性聚氨酯層上,該第一高回彈熱塑性聚氨酯層設置於該高氣密熱塑性聚氨酯層上,該第一高回彈熱塑性聚氨酯層、該高氣密熱塑性聚氨酯層及該第二高回彈熱塑性聚氨酯層之厚度複合比為1:2:1。
- 一種熱塑性聚氨酯球結構之製造方法,包括以下步驟:製作一球內膽層,其係以熱塑性聚氨酯材料製作;以熱塑性聚氨酯紗包覆該球內膽層,以形成一紗線層;製作一表皮層,其係以熱塑性聚氨酯材料製作;及將該表皮層包覆該紗線層,並熱加工處理;其中在製作該球內膽層之步驟中,包括:準備黏度為0.5~2的熱塑性聚氨酯酯粒,並經過一乾燥筒乾燥,使熱塑性聚氨酯酯粒的含水率在20~50ppm間,再使用一熔紡製程,將乾燥後的熱塑性聚氨酯酯粒輸送至一押出機內,熔融後輸送到一計量泵,經該計量泵輸送到一紡絲組件,以噴出熱塑性聚氨酯絲,再經過風溫為10~50℃的冷卻風冷卻後,再以一延伸羅拉裝置(Drawing rollers)進行延伸,再使用一卷繞機(Winder)進行卷繞,以製得200~500 den熱塑性聚氨酯長纖維,再經一球內膽製程,以製得該球內膽層。
- 如請求項5之熱塑性聚氨酯球結構之製造方法,其中在製作該球內膽層之步驟中,包括:製作一第一高回彈熱塑性聚氨酯層、一高氣密熱塑性聚氨酯層及一第二高回彈熱塑性聚氨酯層之步驟,其中以一第一乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第一押出機熔融該熱塑性聚氨酯酯粒,該第一押出機之熔融溫度為160℃-180℃,DIE溫度為180℃,經一第一計量泵,以製作該第一高回彈熱塑性聚氨酯層;以一第二乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第二押出機熔融該熱塑性聚氨酯酯粒,該第二押出機之熔融溫度為160℃-190℃,DIE溫度為180℃,經一第二計量泵,以製作該高氣密熱塑性聚氨酯層;以一第三乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第三押出機熔融該熱塑性聚氨酯酯粒,該第三押出機之熔融溫度為160℃-180℃,DIE溫度為180℃,經一第三計量泵,以製作該第二高回彈熱塑性聚氨酯層;利用一第一淋膜輪冷卻成膜使該高氣密熱塑性聚氨酯層設置於第二高回彈熱塑性聚氨酯層上,該第一高回彈熱塑性聚氨酯層設置於該高氣密熱塑性聚氨酯層上,該第一高回彈熱塑性聚氨酯層、該高氣密熱塑性聚氨酯層及該第二高回彈熱塑性聚氨酯層之厚度複合比為1:2:1。
- 如請求項5之熱塑性聚氨酯球結構之製造方法,其中在製作該表皮層之步驟中,包括:製作一外皮層、一發泡乳膠層及一未發泡乳膠層之步驟,其中以一第四乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第四押出機熔融該熱塑性聚氨酯酯粒,該第四押出機之熔融溫度為185℃-200℃,DIE溫度為185℃,經一第四計量泵,以 製作該外皮層;以一第五乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第五押出機熔融該熱塑性聚氨酯酯粒,且添加微球發泡劑0.5-5.0%,該第五押出機之熔融溫度為160℃-190℃,DIE溫度為185℃,經一第五計量泵,以製作該發泡乳膠層;以一第六乾燥機將熱塑性聚氨酯粒子進行乾燥,使含水率在300ppm以下,並利用一第六押出機熔融該熱塑性聚氨酯酯粒,該第六押出機之熔融溫度為160℃-180℃,DIE溫度為185℃,經一第六計量泵,以製作該未發泡乳膠層;利用一第二淋膜輪冷卻成膜使該發泡乳膠層設置於該未發泡乳膠層上,該外皮層設置於該發泡乳膠層上,該外皮層之厚度為0.1-0.3mm,該發泡乳膠層之厚度為0.4-1.6mm,該未發泡乳膠層之厚度為0.1-0.3mm,且該外皮層、該發泡乳膠層及該未發泡乳膠層之厚度複合比為1:8:1。
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Also Published As
Publication number | Publication date |
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EP3900925A1 (en) | 2021-10-27 |
US20210331040A1 (en) | 2021-10-28 |
TW202140111A (zh) | 2021-11-01 |
US11975243B2 (en) | 2024-05-07 |
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