CN111617450A - 一种竞技训练用球的球片及球的制造方法 - Google Patents
一种竞技训练用球的球片及球的制造方法 Download PDFInfo
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Abstract
本发明公开了一种竞技训练用球的球片及球的制造方法,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,球片弯折处于弯折处高频压合后缝制的边缝平整,不会拱起,使球体圆周更好,另外,上层与下层的泡棉橡胶采用不同的材料,上层采用的EPDM或EVA材料相对来说更稳定,冲击弹性好,防震、不吸水、缓冲性能好、耐腐蚀,而下层采用的PE或SBR材料的性能相对来说更偏向于吸音效果、耐化学性、粘结性能好,弹性相对较低,不透水不透气,耐老化,这样上下两层的材料可以形成功能上的差异化,靠外的部分弹性更重要,下层材料以耐老化为着眼点,符合不同的需求。
Description
技术领域
本发明涉及球类加工技术领域,具体涉及一种竞技训练用球的球片及球的制造方法。
背景技术
历来竞技与训练用球对球体整体外观、圆度、圆周、回弹、吸水率有严格的要求,故市场上竞技及训练用球大致分为以下4种:
1、手缝球
手缝球是将合成皮革或天然皮革的背面用粘贴剂(天然乳胶或合成胶组)粘贴2~4层织布而成的增强层,将复合好的材料使用模具裁断成所需用球的片型形状,且球片每条边缘距边3.0mm处打上针孔后,使用手缝线的线相互用手工缝合的方式缝合成球壳将球壳翻过来使其皮革面向外,然后将内胆塞入复合球片制成的球壳内,将余下4条边进行人工缝合收口,充气后,使具有橡胶弹性的内胎由于其内部的压力如图箭头所示被推压到复合球片的内表面上,由于合成皮革或天然皮革背后粘合了2~4层织物导致球片太硬,不能使用机器缝合,只能使用手工缝合,故导致要求操作工人要熟练,不同操作人员制成的成品质量都不一样,所以生产效率极低,吸水率较差,且质量不稳定,存在大量不确定问题。
2、机缝球
机缝球是将表皮和泡棉结合成的复合层粘合1~2层织物而形成的复合材料后进行裁切成所需用球的片型,使用缝纫线缝合成球壳,需1-4条边不缝制,将球壳开皮革面向外,装入所需的内胎将其气嘴片内胆嘴处用合成胶组粘合后使用机器缝合2-3条边,余下1-2条边因机器无法完成,只能使用人工缝合收口,由于内胎上的增强层迫使成品球边缘被内胎把球接缝处顶起,导致球体圆周和边缝缝线处所承受的压力变大,使球的圆度和耐击打力度差,而且回弹不好,飞行性能、吸水性较差,不符合用于竞技及训练用球的标准。
3、高频粘合球
高频粘合球是将表面厚度0.1~2.0mm和泡棉厚度2.0~4.5mm使用粘合剂粘合形成复合球革,将其复合球革使高频技术把所需用球片型每条边熔断压合成弧形;球片处理完成后使用手工贴合或成型模具贴合的方式在内胎上使用合成胶组进行粘合后进入高温整形,从而形成的成品球,但球体接缝处呈∨字形,开口较大,深度较浅,导致对空气阻力的抑制较差,另外因球片边缝处使用的是高热高压形成的边,故因使用环境、温度影响,边缝易炸开、脱胶,因球壳和球胆不能分离,而导致包装不能完全消气,运输成本高等。
4、折边粘合球
折边粘合球是将表面厚度0.2~2.0mm和泡棉进行粘合形成复合球革,将其裁切成所需用球片型,使用高温200~450℃的压印模具,使其球片反面的EVA距边3.5~5mm的距离机器压出一圈熔融状后,机器进行弯折结合成型,将所有片型折出的边缘高度3.5~5.0mm和球片背面均匀粘上天然乳胶或合成胶组,加热烘干待拼接,将内胆外部均匀上满天然乳胶或合成胶组加热烘干,然后同高频粘合球一样,将球片与球片拼接成2个半球放入成型模具上、下模具内,然后放入球胆定压成型后,高温整形而形成的成品用球,因球壳和球胆完全结合,故不能压扁消气包装,导致运输成本高。
发明内容
本发明旨在提供一种竞技训练用球的球片及球的制造方法。
为实现上述技术目的,本发明采用以下技术方案:一种竞技训练用球的球片,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,外部材料与泡棉橡胶和泡棉橡胶与织物之间通过天然乳胶粘合,所述外部材料采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm。
作为优选,所述外部材料选用PU、PVC或TPU材料。
作为优选,球片的边缘向内2.0-3mm处使用高强度缝纫机缝合。
一种竞技训练用球的制造方法,具体包括以下步骤:
S1、裁皮:裁剪出若干同样形状或不同形状的球片,然后,在球片上印刷图案,干燥;
S2、球片成型:将球片放入高频模具内,采用高频加工法按压球片的周边部,加几千伏电压及几十千赫兹的高频由此所发生的热能使周边部压缩对球片周边进行折边,并在一部分球片的内侧周边形成固定宽度的压边,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,外部材料与泡棉橡胶和泡棉橡胶与织物之间通过天然乳胶粘合,所述外部材料采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm;
S3、缝合:首先将上述周边内侧形成凹槽的球片外面朝里采用高强度缝纫机在球片凹槽部位将球片相互缝合,在缝制最后2片球片时,采用手缝将周边折边球片与其他球片之间相互缝合,形成内面朝外、留有翻转口的球壳;服贴效果与粘合球体保持一致,从而使球体圆周性达到完美。球片与球片之间的缝合图4与折边粘合球显示的球缝呈现的一致,故此种结构能够减轻空气阻力,提高抓握性;
S4、打扣挡眼;球壳与球胆之间的连接通道需在球嘴片上按指示位置打上扣挡眼,扣挡眼宽度按球胆嘴的圆周来打,需在球壳背面气孔处均匀使用粘合剂与球胆气嘴周边均匀使用粘合剂,待其干燥后进行粘合,使球子露出球皮表面后按压至牢固;
S5、装胆:对上述球壳进行翻球,然后在球壳内加入球胆;
S6、封口:将步骤S4中的球体放置于在莲花座内,手缝对球体封口;
S7、成型:球壳内的球胆进行充气(0.6-0.8Bar),充气完成后需使用粘合剂对所有球接缝处进行补胶(为了保证球体的吸水率),待边缝胶水干透后,将球体放入加热整形机内,模具尺寸依据球体圆周大小使用,温度在55-65℃下经过60-90S,气压值设定0.6-0.8Bar情况下整形完成,可将60-90S的热量传输到球体,使球体圆度得到永久形状,热量使边缝胶水充分结合,球体外观看不到缝制线,视觉上和粘合球无异;
S8、充气检测:对球体进行充气试验,在球静置72小时后,再次对其进行检测,包括充气检测和测圆,测圆步骤是通过一个根据球胆直径需要,事先铸造好半球状模具进行测圆,将进行漏气检测合格后的球胆放入半球体模具中旋转进行比对,半球体模具的壁上设有若干个传感器,当球体与模具之间的空隙超过误差允许范围时,传感器会向控制器发出信号触动报警。
作为优选:步骤S3采用的缝制线为尼龙包芯线,大于1000登尼尔。
作为优选:球胆采用缠纱胆或者贴布胆,以上两种球胆因外层增加了加强层有助于提升足球、排球、手球的坚固性和圆度。
本发明所采用的技术方案具有以下有益效果:球片弯折处于弯折处高频压合后缝制的边缝平整,不会拱起,使球体圆周更好,另外,上层与下层的泡棉橡胶采用不同的材料,上层采用的EPDM或EVA材料相对来说更稳定,冲击弹性好,防震、不吸水、缓冲性能好、耐腐蚀,而下层采用的PE或SBR材料的性能相对来说更偏向于吸音效果、耐化学性、粘结性能好,弹性相对较低,不透水不透气,耐老化,这样上下两层的材料可以形成功能上的差异化,靠外的部分弹性更重要,下层材料以耐老化为着眼点,符合不同的需求;球片边缝使用粘合剂粘合使球体耐水性更好;由于此种结构的构造使球体耐冲击力增强(经测试50km时速撞击10000次不破);过程多数可以通过机器完成,生产效率高;本发明可以进行压缩50%~80%消气包装出运,使其运输成本降低至少50%,商业优势明显;具备手缝球和粘合球所有的优点;所以,可以提供高、中、低档的竞技及训练用球,对球类产业有很大的贡献。
说明书附图
图1为本发明竞技训练用球的球片的横截面结构示意图;
图2为本发明竞技训练用球的制造方法流程图中球片材料;
图3为本发明球片裁皮后的形状示意图;
图4为球片两侧压合后的示意图;
图5为球片缝合时的示意图;
图6为本发明使用的缠纱胆结构示意图;
图7为本发明使用的贴布胆结构示意图
图8为球嘴片和球胆嘴结合处的示意图;
图9为使用缠纱胆的球体收边缝合处的示意图;
图10为使用贴布胆的球体收边缝合处的示意图。
其中,1、外部材料;2、泡棉橡胶;3、织物;4、天然乳胶。
具体实施方式
下面详细描述本发明的实施例,所述实施例的示例在附图中示出,其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的,仅用于解释本发明,而不能理解为对本发明的限制。
在本发明的描述中,除非另有规定和限定,需要说明的是,术语“安装”、“相连”、“连接”应做广义理解,例如,可以是机械连接或电连接,也可以是两个元件内部的连通,可以是直接相连,也可以通过中间媒介间接相连。对于本领域的普通技术人员而言,可以根据具体情况理解上述术语的具体含义。
如图1所示,一种竞技训练用球的球片,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料1、泡棉橡胶2、织物3、泡棉橡胶2、织物3,外部材料1与泡棉橡胶2和泡棉橡胶2与织物3之间通过天然乳胶4粘合,所述外部材料1采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶2采用EPDM或EVA材料,下层的泡棉橡胶2采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm。
作为优选,所述外部材料1选用PU、PVC或TPU材料。
作为优选,球片的边缘向内2.0-3mm处使用高强度缝纫机缝合。
一种竞技训练用球的制造方法,参见图2至图10,具体包括以下步骤:
S1、裁皮:裁剪出若干同样形状或不同形状的球片,然后,在球片上印刷图案,干燥;
S2、球片成型:将球片放入高频模具内,采用高频加工法按压球片的周边部,加几千伏电压及几十千赫兹的高频由此所发生的热能使周边部压缩对球片周边进行折边,并在一部分球片的内侧周边形成固定宽度的压边,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,外部材料与泡棉橡胶和泡棉橡胶与织物之间通过天然乳胶粘合,所述外部材料采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm;
S3、缝合:首先将上述周边内侧形成凹槽的球片外面朝里采用高强度缝纫机在球片凹槽部位将球片相互缝合,在缝制最后2片球片时,采用手缝将周边折边球片与其他球片之间相互缝合,形成内面朝外、留有翻转口的球壳;服贴效果与粘合球体保持一致,从而使球体圆周性达到完美。球片与球片之间的缝合图4与折边粘合球显示的球缝呈现的一致,故此种结构能够减轻空气阻力,提高抓握性;
S4、打扣挡眼;球壳与球胆之间的连接通道需在球嘴片上按指示位置打上扣挡眼,扣挡眼宽度按球胆嘴的圆周来打,需在球壳背面气孔处均匀使用粘合剂与球胆气嘴周边均匀使用粘合剂,待其干燥后进行粘合,使球子露出球皮表面后按压至牢固;
S5、装胆:对上述球壳进行翻球,然后在球壳内加入球胆;
S6、封口:将步骤S4中的球体放置于在莲花座内,手缝对球体封口;
S7、成型:球壳内的球胆进行充气(0.6-0.8Bar),充气完成后需使用粘合剂对所有球接缝处进行补胶(为了保证球体的吸水率),待边缝胶水干透后,将球体放入加热整形机内,模具尺寸依据球体圆周大小使用,温度在55-65℃下经过60-90S,气压值设定0.6-0.8Bar情况下整形完成,可将60-90S的热量传输到球体,使球体圆度得到永久形状,热量使边缝胶水充分结合,球体外观看不到缝制线,视觉上和粘合球无异;
S8、充气检测:对球体进行充气试验,在球静置72小时后,再次对其进行检测,包括充气检测和测圆,测圆步骤是通过一个根据球胆直径需要,事先铸造好半球状模具进行测圆,将进行漏气检测合格后的球胆放入半球体模具中旋转进行比对,半球体模具的壁上设有若干个传感器,当球体与模具之间的空隙超过误差允许范围时,传感器会向控制器发出信号触动报警。
作为优选:步骤S3采用的缝制线为尼龙包芯线,大于1000登尼尔。
作为优选:球胆采用缠纱胆或者贴布胆,以上两种球胆因外层增加了加强层有助于提升足球、排球、手球的坚固性和圆度。
本发明所采用的技术方案具有以下有益效果:球片弯折处于弯折处高频压合后缝制的边缝平整,不会拱起,使球体圆周更好,另外,上层与下层的泡棉橡胶采用不同的材料,上层采用的EPDM或EVA材料相对来说更稳定,冲击弹性好,防震、不吸水、缓冲性能好、耐腐蚀,而下层采用的PE或SBR材料的性能相对来说更偏向于吸音效果、耐化学性、粘结性能好,弹性相对较低,不透水不透气,耐老化,这样上下两层的材料可以形成功能上的差异化,靠外的部分弹性更重要,下层材料以耐老化为着眼点,符合不同的需求;球片边缝使用粘合剂粘合使球体耐水性更好;由于此种结构的构造使球体耐冲击力增强(经测试50km时速撞击10000次不破);过程多数可以通过机器完成,生产效率高;本发明可以进行压缩50%~80%消气包装出运,使其运输成本降低至少50%,商业优势明显;具备手缝球和粘合球所有的优点;所以,可以提供高、中、低档的竞技及训练用球,对球类产业有很大的贡献。
在本说明书的描述中,参考术语“一个实施例”、“示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中,对上述术语的示意性表述不一定指的是相同的实施例或示例。而且,描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
以上显示和描述了本发明的基本原理和主要特征。本行业的技术人员应该了解,本发明不受上述实施例的限制,上述实施例和说明书中描述的只是说明本发明的原理,在不脱离本发明精神和范围的前提下,本发明还会有各种变化和改进,这些变化和改进都落入要求保护的本发明范围内。本发明要求保护范围由所附的权利要求书及其等效物界定。
Claims (6)
1.一种竞技训练用球的球片,其特征在于,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,外部材料与泡棉橡胶和泡棉橡胶与织物之间通过天然乳胶粘合,所述外部材料采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm。
2.根据权利要求1所述的球片,其特征在于,所述外部材料选用PU、PVC或TPU材料。
3.根据权利要求1所述的球片,其特征在于,球片的边缘向内2.0-3mm处使用高强度缝纫机缝合。
4.一种竞技训练用球的制造方法,其特征在于,具体包括以下步骤:
S1、裁皮:裁剪出若干同样形状或不同形状的球片,然后,在球片上印刷图案,干燥;
S2、球片成型:将球片放入高频模具内,采用高频加工法按压球片的周边部,加几千伏电压及几十千赫兹的高频由此所发生的热能使周边部压缩对球片周边进行折边,并在一部分球片的内侧周边形成固定宽度的压边,球片总厚度为5-7mm,球片边缘向内3.5-4.5mm的一圈经过高频设备加工使得其厚度少于未加工部分的厚度的一半,球片从上到下依次为外部材料、泡棉橡胶、织物、泡棉橡胶、织物,外部材料与泡棉橡胶和泡棉橡胶与织物之间通过天然乳胶粘合,所述外部材料采用合成皮革,厚度为0.15-1.6mm,上层的泡棉橡胶采用EPDM或EVA材料,下层的泡棉橡胶采用PE或SBR材料,泡棉橡胶层的厚度为2-5mm,硬度为23-28度,织物层厚度为0.1-0.5mm;
S3、缝合:首先将上述周边内侧形成凹槽的球片外面朝里采用高强度缝纫机在球片凹槽部位将球片相互缝合,在缝制最后2片球片时,采用手缝将周边折边球片与其他球片之间相互缝合,形成内面朝外、留有翻转口的球壳;
S4、打扣挡眼;球壳与球胆之间的连接通道需在球嘴片上按指示位置打上扣挡眼,扣挡眼宽度按球胆嘴的圆周来打,需在球壳背面气孔处均匀使用粘合剂与球胆气嘴周边均匀使用粘合剂,待其干燥后进行粘合,使球子露出球皮表面后按压至牢固;
S5、装胆:对上述球壳进行翻球,然后在球壳内加入球胆;
S6、封口:将步骤S4中的球体放置于在莲花座内,手缝对球体封口;
S7、成型:球壳内的球胆进行充气(0.6-0.8Bar),充气完成后需使用粘合剂对所有球接缝处进行补胶,待边缝胶水干透后,将球体放入加热整形机内,模具尺寸依据球体圆周大小使用,温度在55-65℃下经过60-90S,气压值设定0.6-0.8Bar情况下整形完成,可将60-90S的热量传输到球体,使球体圆度得到永久形状,热量使边缝胶水充分结合;
S8、充气检测:对球体进行充气试验,在球静置72小时后,再次对其进行检测,包括充气检测和测圆,测圆步骤是通过一个根据球胆直径需要,事先铸造好半球状模具进行测圆,将进行漏气检测合格后的球胆放入半球体模具中旋转进行比对,半球体模具的壁上设有若干个传感器,当球体与模具之间的空隙超过误差允许范围时,传感器会向控制器发出信号触动报警。
5.根据权利要求4所述的一种竞技训练用球的制造方法,其特征在于:步骤S3采用的缝制线为尼龙包芯线,大于1000登尼尔。
6.根据权利要求1所述的一种竞技训练用球的制造方法,其特征在于:球胆采用缠纱胆或者贴布胆。
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