CN108115957A - 一种不脱胶无裂缝的机贴篮球制备方法 - Google Patents

一种不脱胶无裂缝的机贴篮球制备方法 Download PDF

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CN108115957A
CN108115957A CN201611073215.1A CN201611073215A CN108115957A CN 108115957 A CN108115957 A CN 108115957A CN 201611073215 A CN201611073215 A CN 201611073215A CN 108115957 A CN108115957 A CN 108115957A
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machine
agent
basketball
tire
leatheret
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姚军伟
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Jiangsu Tianling Sports Goods Co Ltd
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Abstract

本发明涉及篮球制备技术领域，具体涉及一种不脱胶无裂缝的机贴篮球制备方法，它采用如下的方法步骤：步骤一：中胎制作，其流程为：混炼胶‑‑出片‑‑裁皮‑‑绕纱‑‑‑贴八片；步骤二：贴皮球制作，其流程为：裁皮‑‑高频热转商标‑‑皮片涂布胶‑‑机贴机包皮‑‑热硫化交联‑‑冷定型‑‑上球子‑‑充气、定压‑‑成品贴皮球；它免除中胎硫化及后道工艺，通过一次性将人造皮和未硫化的橡胶中胎压合，在经低温.低压热交联硫化，使人造皮和中胎橡胶片层以及绕纱层.内胆层紧密交联，永不翘边；它具有工艺简单，简化流程，省时，省工和省能源等优点。

Description

一种不脱胶无裂缝的机贴篮球制备方法
【技术领域】
本发明涉及篮球制备技术领域，具体涉及一种不脱胶无裂缝的机贴篮球制备方法。
【背景技术】
随着人们的生活水平的提高，人们对于健身运动的要求也日益提高，篮球作为一种健身运动被人们所喜欢，特别是当下一些青少年更是喜欢打篮球。贴皮篮球作为人们健身的运动用品，一方面市场对贴皮篮球制造工艺的环保要求越来越高。尽可能不要用到对人身有害的溶剂，特别是含苯的有机溶剂。二方面市场价格竞争很激烈，特别是材料和人工成本的竞争。三方面就是市场对贴皮篮球的最直接的质量需求：粘接的人造皮不容易脱胶或翘边以及人造皮和橡胶筋沟无任何裂缝。
传统的篮球基本制作工艺包括中胎制作和贴皮加工。其中：中胎成品制作工艺步骤是：混炼胶--出片--裁皮--绕纱--贴八片--中胎硫化--成品中胎整理--仓储。从中胎贴八片完毕，要经过硫化，制成成品中胎；这环节一方面要耗用相当的蒸汽.空压能源，大约合计费用：0.55元/PSC.二方面耗用人力资源，多出这个环节，人力成本大约耗费：0.2元/PCS。
贴皮加工工艺：裁皮--高频热转商标--削边--皮片上胶--中胎打磨--中胎上胶--皮片.中胎烘烤--手工贴皮--热整形--上球子--充气定压--成品贴皮球。从贴皮加工工艺中可以看出：
1)削边、中胎打磨，中胎上胶工艺操作耗费相当人力资源，费用约：1.0元。
2)因为中胎上胶要用到胶水，胶水费用基本耗费：0.8元/PCS；胶水调制需要一定量的溶剂，溶剂挥发造成大气污染，对此环境下的员工身体健康有不利影响。即此工艺不适应较高的环保要求。
3)因为胶水质量，员工上胶，中胎抛磨作业稳定性......以及其他配合作业的稳定性，对人造革和橡胶中胎粘接强度也会带来不稳定的因素，容易造成成品贴皮球在消费者使用或撞击检测过程中出现脱胶、翘皮现象。影响产品品质的稳定性。
4)传统法工艺根本解决不了人造皮和橡胶筋沟有裂缝存在。这样就决定这样制作的贴皮球出货一般只能采用全充气出货，材积数加大，出货运输成本明显增加。
【发明内容】
本发明的目的在于针对现有技术的缺陷和不足，提供一种设计合理、使用方便的一种不脱胶无裂缝的机贴篮球制备方法，它免除中胎硫化及后道工艺，通过一次性将人造皮和未硫化的橡胶中胎热压合，在经低温.低压热交联硫化，使人造皮和中胎橡胶片层以及绕纱层、内胆层紧密交联，正真实现永不翘边；且人造皮和中胎筋沟实现无缝接着。它具有工艺简单，简化流程，省时，省工和省能源等优点。
本发明所述的一种不脱胶无裂缝的机贴篮球制备方法，它采用如下的方法步骤：
步骤一：中胎制作，其流程为：混炼胶--出片--裁皮--绕纱---贴八片；
1)优化混炼胶配方：在配合体系中加入具有加强人造皮和中胎胶片、绕纱层、内胆层热交联接着的原料和配合剂，实现在贴皮篮球低温，低压热硫化交联时，能使人造皮的涂布胶膜和中胎胶片、绕纱层、内胆层紧密交联；
2)在胶料配方中添加发泡剂，使中胎橡胶层发泡，使成品球手感触抓好的发泡效果；
3)裁皮：按中胎八片模大小和形状，设计的八片或两片梅花刀模裁切中胎橡胶层胶片。
4)贴八片：将裁切好的皮片准确排布到八片模内，并将缠绕好的纱球放入，合模后利用气压将橡胶片和纱球贴合紧密，形成未硫化中胎半成品。
5)省去硫化--上球子--充气定压--试气等工艺流程；
步骤二：贴皮球制作，其流程为：裁皮--高频热转商标--皮片涂布胶--机贴机包皮--热硫化交联--冷定型--上球子--充气、定压--成品贴皮球；
机贴热包皮：其步骤如下：
a)采用机贴机，一次性将涂布好胶水经烘干成膜的人造皮按形状有序地排布到机贴机模具固定的片格内；再采用机贴机，一次性将人造皮完整无误的粘贴到橡胶中胎上；
b)然后再将未硫化的半成品中胎放入模具内一体热贴合成型，形成半成品机贴篮球；
c)热硫化交联--冷定型:将半成品机贴篮球，放入硫化模中，硫化模中的纹路可根据事先设置为各种需求纹路，例如八片型颗粒纹路；然后通过低温.低压热硫化交联，使混炼胶中的交联接着原料和配合剂充分发挥了立体交联粘接功效，使人造皮、橡胶片层、纱球实现了紧密接着交联，从而使得人造皮、橡胶筋沟实现无缝对接，形成贴皮篮球。
进一步地，所述步骤一中原料和配合剂，按质量百分比的组成配方如下：
天然胶20％-40％、合成胶5％-23％、热塑性弹性体0.5％-3％、分散流动剂0.5％-0.9、补强剂(白炭黑)3％-5％、酸碱调节剂(碳酸镁)3％-5％、增量粉剂(轻质碳酸钙)30％-35％、防老剂0.8％-1.08％、增粘树脂1％-1.5％、硬脂酸0.4％-0.48％、氧化锌2％-3％、防焦剂0.1％-0.12％、活性剂0.1％-0.14％、促进剂1％-1.5％、硫化剂(硫磺)0.8％-1.5％、着色剂(色粉.色胶)1.2％-1.6％、发泡剂1％-2％。
进一步地，所述步骤一中，在人造皮上涂抹上胶水经烘干成膜，其胶膜采用的胶水按质量百分比的组成配方如下：
氯丁胶10％-22％、天然胶1％-10％、热缩性弹性体0.1％-2％、防焦剂(氧化镁)0.7％-0.9％、活性硫化剂(氧化锌)1％-1.5％、加工助剂(硬脂酸)0.1％-0.15％、促进剂0.15％-0.25％、补强剂(白炭黑)5％-8％、偶联剂0.2％-0.35％、增粘树脂1％-8％、消泡剂0.08％-0.1％、环保稀释剂50％-60％。
进一步地，所述热交联硫化的热源为电热或蒸汽。
进一步地，所述硫化模可以设置不同纹烙，从而实现成篮球表面有不同的纹路。
进一步地，所述半成品篮球在特定纹烙的模具中热硫化时，人造革从模具内壁上传导热量，使人造革变软，形成粘流相，同时在空压的推挤下，挤进模具内壁，从而形成特定纹烙在球片上。
本发明有益效果为：本发明所述的一种不脱胶无裂缝的机贴篮球制备方法，它免除中胎硫化及后道工艺，通过一次性将人造皮和未硫化的橡胶中胎定位压合，在经低温.低压热交联硫化，使人造皮和中胎橡胶片层以及绕纱层、内胆层紧密交联，正真实现永不翘边；它具有工艺简单，简化流程，省时，省工和省能源等优点。
【具体实施方式】
下面以具体实施例来详细说明本发明，其中的示意性实施例以及说明仅用来解释本发明，但并不作为对本发明的限定。
本具体实施方式所述的一种不脱胶无裂缝的机贴篮球制备方法，它采用如下的方法步骤：
步骤一：中胎制作，其流程为：混炼胶--出片--裁皮--绕纱---贴八片；
1)优化混炼胶配方：在配合体系中加入具有加强人造皮和中胎胶片、绕纱层、内胆层热交联接着的原料和配合剂，实现在贴皮篮球低温，低压热硫化交联时，能使人造皮的涂布胶膜和中胎胶片、绕纱层、内胆层紧密交联；
2)在胶料配方中添加发泡剂，使中胎橡胶层发泡，使成品球手感触抓好的发泡效果；
3)贴胶片：用适当裁刀将橡胶皮片裁切，并通过包皮模，将胶片贴合到纱球外部，形成未硫化的半成品中胎。
4)省去半成品中胎硫化--上球子--充气定压--试气等工艺流程；
步骤二：贴皮球制作，其流程为：裁皮--高频热转商标--皮片涂布胶--机贴机包皮--热硫化交联--冷定型--上球子--充气、定压--成品贴皮球；
机贴热包皮：其步骤如下：
a)采用机贴机，一次性将涂布胶膜的人造皮按形状有序地排布到机贴机模具固定的片格内；再采用机贴机，一次性将人造皮完整无误的粘贴到橡胶中胎上；
b)然后再将未硫化的半成品中胎放入模具内和排布好的人造皮一体热贴合成型，形成半成品机贴篮球；
c)热硫化交联--冷定型:将半成品机贴篮球，放入硫化模中，硫化模中的纹路可根据事先设置为相应纹路，例如八片型颗粒纹路；然后通过低温.低压热硫化交联，使混炼胶中的交联接着成分充分发挥了立体交联粘接功效，使人造皮、橡胶皮、纱球实现了紧密接着交联，从而使得人造皮、橡胶筋沟实现无缝对接，形成贴皮篮球。
作为本发明的一种优选，所述步骤一中原料和配合剂，按质量百分比的组成配方如下：
天然胶20％-40％、合成胶5％-23％、热塑性弹性体0.5％-3％、分散流动剂0.5％-0.9、补强剂(白炭黑)3％-5％、酸碱调节剂(碳酸镁)3％-5％、增量粉剂(轻质碳酸钙)30％-35％、防老剂0.8％-1.08％、增粘树脂1％-1.5％、硬脂酸0.4％-0.48％、氧化锌2％-3％、防焦剂0.1％-0.12％、活性剂0.1％-0.14％、促进剂1％-1.5％、硫化剂(硫磺)0.8％-1.5％、着色剂(色粉.色胶)1.2％-1.6％、发泡剂1％-2％。
作为本发明的一种优选，所述步骤一中，在人造皮上涂抹上胶膜，其胶膜采用的胶水按质量百分比的组成配方如下：
氯丁胶10％-22％、天然胶1％-10％、热缩性弹性体0.1％-2％、防焦剂(氧化镁)0.7％-0.9％、活性硫化剂(氧化锌)1％-1.5％、加工助剂(硬脂酸)0.1％-0.15％、促进剂0.15％-0.25％、补强剂(白炭黑)5％-8％、偶联剂0.2％-0.35％、增粘树脂1％-8％、消泡剂0.08％-0.1％、环保稀释剂50％-60％。
作为本发明的一种优选，所述热交联硫化的热源可为电热或蒸汽。
作为本发明的一种优选，所述硫化模可以设置不同纹烙，从而实现成篮球表面有不同的纹路。
作为本发明的一种优选，所述半成品篮球在特定纹烙的模具中热硫化时，人造革从模具内壁上传导热量，使人造革变软，形成粘流相，同时在空压的推挤下，挤进模具内壁，从而形成特定纹烙在球片上。
本发明与传统的篮球制作工艺相比：
本发明省去半成品中胎硫化--上球子--充气定压--试气等工艺流程，具有以下有益效果：
1)人工成本大约可以节省：0.25元/PCS.
2)蒸汽.电力能源大约可以节省：0.55元/PCS.同时也可以节省一定的成品中胎仓储库容。
本发明简化了：中胎抛磨、中胎上胶、皮片削边，具有以下有益效果：
1)人工成本大约可以节省：1.0元/PCS；
2)物料成本大约可以节省：1.5元/PCS；
3)因为胶水少用，从而减少有机溶剂的挥发，减少车间的空气污染，对操作工的身体健康也得到一定的保障。
本发明中，标准固定的刀模决定了人造革裁皮的大小；标准定位的机贴决定了球片位置的准确，
本发明解决传统制备篮球中的下列技术问题：
1)中胎无需进行单独硫化制成成品中胎及中胎整理、保存等一系列作业。
2)成品中胎无需打磨，上胶；皮片无需削边工艺。
3)机器、模具定位贴皮代替人力纯手工贴皮。
4)贴皮球皮革表面纹烙更容易按需求变化，且变化成本较低。
5)产品出货由现有技术的全充气包装转化成半消气包装，使出货材积数变小，运费成本降低。
本发明的成品贴皮篮球的特性：无缝、不脱胶、不翘边、耐撞击、平衡性好、弹跳好，也直接实现了产品出货可以半消气包装，有效减小了产品包装材积数，有效地降低产品出货运输成本。
本发明所述的一种不脱胶无裂缝的机贴篮球制备方法，它免除中胎硫化及后道工艺，通过一次性将人造皮和未硫化的橡胶中胎热压合，在经低温.低压热交联硫化，使人造皮和中胎橡胶片层以及绕纱层.内胆层紧密交联，正真实现永不翘边；且实现人造皮和橡胶中胎筋沟无缝接着。它具有工艺简单，简化流程，省时，省工和省能源等优点。
以上所述仅是本发明的较佳实施方式，故凡依本发明专利申请范围所述的特征及原理所做的等效变化或修饰，均包括于本发明专利申请范围内。

Claims (6)

1.一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：它采用如下的方法步骤：
步骤一：中胎制作，其流程为：混炼胶--出片--裁皮--绕纱---贴八片；
1)优化混炼胶配方：在配合体系中加入具有加强人造皮和中胎胶片、绕纱层、内胆层热交联接着的原料和配合剂，实现在贴皮篮球低温，低压热硫化交联时，能使人造皮的涂布胶膜和中胎胶片、绕纱层、内胆层紧密交联；
2)在胶料配方中添加发泡剂，使中胎橡胶层发泡，使成品球手感触抓好的发泡效果；
3)裁皮：按中胎八片模大小和形状，设计的八片或两片梅花刀模裁切中胎橡胶层胶片；
4)贴八片：将裁切好的皮片准确排布到八片模内，并将缠绕好的纱球放入，合模后利用气压将橡胶片和纱球贴合紧密，形成未硫化中胎半成品；
5)省去硫化--上球子--充气定压--试气等工艺流程；
步骤二：贴皮球制作，其流程为：裁皮--高频热转商标--皮片涂布胶--机贴机包皮--热硫化交联--冷定型--上球子--充气、定压--成品贴皮球；
机贴热包皮：其步骤如下：
a)采用机贴机，一次性将涂布好胶水，烘干成膜的人造皮按形状有序地排布到机贴机模具固定的片格内；再将未硫化半成品中胎放入机贴模内，采用机贴机，一次性将人造皮完整无误的粘贴到橡胶中胎上；形成半成品机贴篮球。
b)热硫化交联--冷定型:将半成品机贴篮球，放入硫化模中，硫化模中的纹路可根据事先设置为各种需求纹路，例如八片型颗粒纹路；然后通过低温.低压热硫化交联，使混炼胶中的交联接着原料和配合剂充分发挥了立体交联粘接功效，使人造皮、橡胶皮、纱球实现了紧密接着交联，从而使得人造皮、橡胶筋沟实现无缝对接，形成贴皮篮球。
2.根据权利要求1所述的一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：所述步骤一中原料和配合剂，按质量百分比的组成配方如下：
天然胶20％-40％、合成胶5％-23％、热塑性弹性体0.5％-3％、分散流动剂0.5％-0.9、补强剂(白炭黑)3％-5％、酸碱调节剂(碳酸镁)3％-5％、增量粉剂(轻质碳酸钙)30％-35％、防老剂0.8％-1.08％、增粘树脂1％-1.5％、硬脂酸0.4％-0.48％、氧化锌2％-3％、防焦剂0.1％-0.12％、活性剂0.1％-0.14％、促进剂1％-1.5％、硫化剂(硫磺)0.8％-1.5％、着色剂(色粉.色胶)1.2％-1.6％、发泡剂1％-2％。
3.根据权利要求1所述的一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：所述步骤一中，在人造皮上涂抹上胶水，经烘干成膜，其胶膜采用的胶水按质量百分比的组成配方如下：
氯丁胶10％-22％、天然胶1％-10％、热缩性弹性体0.1％-2％、防焦剂(氧化镁)0.7％-0.9％、活性硫化剂(氧化锌)1％-1.5％、加工助剂(硬脂酸)0.1％-0.15％、促进剂0.15％-0.25％、补强剂(白炭黑)5％-8％、偶联剂0.2％-0.35％、增粘树脂1％-8％、消泡剂0.08％-0.1％、环保稀释剂50％-60％。
4.根据权利要求1所述的一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：所述热交联硫化的热源为电热或蒸汽。
5.根据权利要求1所述的一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：所述硫化模可以设置不同纹烙，从而实现成篮球表面有不同的纹路。
6.根据权利要求1所述的一种不脱胶无裂缝的机贴篮球制备方法，其特征在于：所述半成品篮球在特定纹烙的模具中热硫化时，人造革从模具内壁上传导热量，使人造革变软，形成粘流相，同时在空压的推挤下，挤进模具内壁，从而形成特定纹烙在球片上。
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