Patent Description:
A conventional football structure is formed of a rubber bladder, a nylon long fiber, ethylene-vinyl acetate copolymer (EVA) foam and other materials. However, a conventional football manufacturing process requires a solvent, which will harm the environment and does not satisfy the requirement for environmental protection. In addition, in the conventional football manufacturing process, an adhesive is used to bond the layers. Since the materials of the layers are different, the peeling strength between the layers is not good, so that the overall peeling strength of the conventional football structure is insufficient. <CIT> discloses a Ball, in particular football, comprising: a bladder which has a majority weight component of a material of a first material class, at least one intermediate layer, wherein the at least one intermediate layer is arranged exterior to the bladder, and wherein the at least one intermediate layer has a majority weight component of the material of the first material class, and at least one exterior layer, wherein the at least one exterior layer is arranged exterior to the at least one intermediate layer, and wherein the at least one exterior layer has a majority weight component of the material of the first material class. In <CIT> a game ball is disclosed that includes a polymer foam layer processed with an inert fluid blowing agent, such as nitrogen. The polymer foam may be a polyolefin material, such as polyethylene, polypropylene, and ethylvinylacetate, and the inert fluid blowing agent may have a relatively high-purity. The polymer foam may be manufactured with a process that includes impregnating a polymer with the inert fluid blowing agent and expanding the polymer by heating the polymer above a softening temperature of the polymer, reducing a fluid pressure surrounding the polymer, and cooling the polymer. The game ball may be a soccerball, football, or volleyball, for example, that includes the polymer foam. <CIT> discloses an environmental protection solid sphere with high elasticity and strong wearability, it includes courage and the synthetic cortex of PU among TPU foaming inner bag, the PU, and TPU foaming inner bag be inner bag bearing structure, sets up in inside, and its outside twines the winding yarn layer, and the courage laminating is in the outside on yarn winding layer among the PU, and the synthetic cortex of PU passes through the laminate outside of in PU courage of adhesive layer. The utility model discloses an advantage: adopt TPU expanded material as the inner bag, definitely high -elastic, the thorn is broken forever, never aerify, and the environmental protection, nontoxic tasteless, high strength is wear -resisting, one year for the rubber ball, this product ofusefulness ball <NUM> years is not bad, increasing the yarn winding layer in TPU expanded material's the outside and tieing, pressure that the original circumference that increases the inner bag bore increases spheroidal strike breaking strength, too hard, the also poor shortcoming that rebounds in the thick institute in the yarn winding layer spheroid surface of causing has been solved, more filleda vacancy direct intensity that cloth did not reach and circularity slewing rate to courage in the outside on yarn winding layer increases one deck PU. <CIT> discloses a game ball that includes a polymer foam layer processed with an inert fluid blowing agent, such as nitrogen. The polymer foam may be a polyolefin material, such as polyethylene, polypropylene, and ethylvinylacetate, and the inert fluid blowing agent may have a relatively high-purity. The polymer foam may be manufactured with a process that includes impregnating a polymer with the inert fluid blowing agent and expanding the polymer by heating the polymer above a softening temperature of the polymer, reducing a fluid pressure surrounding the polymer, and cooling the polymer. The game ball may be a soccerball, football, or volleyball, for example, that includes the polymer foam.

In accordance with one aspect of the present disclosure, a TPU ball structure according to the claims is disclosed.

Aspects of the present disclosure are understood from the following detailed description when read with the accompanying figures.

It is to be understood that the following disclosure provides many different embodiments or examples, for implementing different features of various embodiments. Specific examples of components and arrangements are described below to simplify the present disclosure. The present disclosure may, however, be embodied in many different forms and should not be construed as being limited to the embodiments set forth herein; rather, these embodiments are provided so that this description will be thorough and complete, and will fully convey the present disclosure to those of ordinary skill in the art.

It will be understood that when an element is referred to as being "on" another element, it can be directly on the other element or intervening elements may be present.

It will be understood that singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise.

It will be further understood that terms; such as those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and the present disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

Referring to <FIG>, it is a schematic structural diagram showing a TPU ball structure according to an embodiment of the present invention. In an embodiment, the TPU ball structure <NUM> of the present invention includes: a ball bladder layer <NUM>, a yarn layer <NUM> and a surface layer <NUM>. The ball bladder layer <NUM> is made of a thermoplastic polyurethane (TPU) material. The yarn layer <NUM> is made of a TPU material, and the yarn layer <NUM> is disposed to cover the ball bladder layer <NUM>. The surface layer <NUM> is made of a TPU material, and the surface layer <NUM> is disposed to cover the yarn layer <NUM>. The TPU ball structure <NUM> of the present invention can be applied to various types of balls, such as footballs, but not limited to the above.

In an embodiment, the ball bladder layer <NUM> is made by winding a TPU long fiber by a ball bladder process. Referring to <FIG>, it is a schematic structural diagram showing a ball bladder layer according to an embodiment of the present invention. In an embodiment, the ball bladder layer <NUM> includes a first high-resilience TPU layer <NUM>, a high-airtightness TPU layer <NUM> and a second high-resilience TPU layer <NUM>. The high-airtightness TPU layer <NUM> is disposed on the second high-resilience TPU layer <NUM>, and the first high-resilience TPU layer <NUM> is disposed on the high-airtightness TPU layer <NUM>. The thickness composite ratio of the first high-resilience TPU layer <NUM> to the high-airtightness TPU layer <NUM> to the second high-resilience TPU layer <NUM> is <NUM>:<NUM>:<NUM>. In an embodiment, the thickness of the first high-resilience TPU layer may be <NUM>, the thickness of the high-airtightness TPU layer may be <NUM>, and the thickness of the second high-resilience TPU layer may be <NUM>.

In an embodiment, the yarn layer <NUM> is made of TPU winding yarn or TPU hot melt yarn. The TPU winding yarn or the TPU hot melt yarn may be a TPU elastomer. The yarn layer <NUM> may be subjected to hot-working treatment to bond the ball bladder layer <NUM> and the surface layer <NUM> by melting.

Referring to <FIG>, it is a schematic structural diagram showing a surface layer according to an embodiment of the present invention. In an embodiment, the surface layer <NUM> includes an outer surface layer <NUM> and a latex layer. The latex layer includes a foamed latex layer <NUM> and an unfoamed latex layer <NUM>. The foamed latex layer <NUM> is disposed on the unfoamed latex layer <NUM>, and the outer surface layer <NUM> is disposed on the foamed latex layer <NUM>. The thickness composite ratio of the outer surface layer <NUM> to the foamed latex layer <NUM> to the unfoamed latex layer <NUM> is <NUM>:<NUM>:<NUM>. In an embodiment, the thickness of the outer surface layer <NUM> is <NUM>-<NUM>, the thickness of the foamed latex layer <NUM> is <NUM>-<NUM>, and the thickness of the unfoamed latex layer <NUM> is <NUM>-<NUM>. In an embodiment, the thickness of the outer surface layer <NUM> may be <NUM>, the thickness of the foamed latex layer <NUM> may be <NUM>, and the thickness of the unfoamed latex layer <NUM> may be <NUM>.

The TPU ball structure <NUM> of the present invention is made of the TPU material only, which satisfies the requirement for environmental protection and is recyclable. There is no need to use any solvent so as to avoid harming the environment. In addition, the layers of the TPU ball structure <NUM> of the present invention are made of the same TPU material, and there is no need to use an adhesive to bond the layers. According to the TPU ball structure <NUM> of the present invention, the layers can be bonded by melting. Therefore, the peeling strength between the layers can be increased, so that the overall peeling strength of the TPU ball structure <NUM> of the present invention can be increased.

Referring to <FIG>, it is a schematic flowchart showing a manufacturing method of a TPU ball structure. Referring to <FIG> and <FIG> together, with reference to step S41 first, the ball bladder layer <NUM> is made by using a TPU material. Optionally the step of making the ball bladder layer includes: TPU pellets with the viscosity of <NUM>-<NUM> are prepared and dried by a drying cylinder so that the moisture content of the TPU pellets is <NUM>-<NUM> ppm. By using a melt-spinning process, the dried TPU pellets are transported to an extruder, melted and transported to a metering pump, and transported to a spinning assembly through the metering pump to eject a TPU filament. The TPU filament is then cooled by cooling air at the temperature of <NUM>-<NUM>, drawn by drawing rollers, and wound by a winder to obtain a <NUM>-<NUM> den TPU long fiber. The TPU long fiber is subjected to a ball bladder process to obtain the ball bladder layer <NUM>.

Optionally the TPU long fiber has a physical property of <NUM>-<NUM>/d, a <NUM>% initial strength of <NUM>-<NUM> kgf and an elongation of <NUM>-<NUM>%.

Referring to <FIG>, <FIG> and <FIG> together, optionally the step of making the ball bladder layer <NUM> includes a step of making a first high-resilience TPU layer <NUM>, a high-airtightness TPU layer <NUM> and a second high-resilience TPU layer <NUM>. TPU particles are dried by a first dryer so that the moisture content is <NUM> ppm or below, and the TPU pellets are melted by a first extruder. The melting temperature of the first extruder is <NUM>-<NUM>. Optionally the melting temperature of the first extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the first high-resilience TPU layer <NUM> is made through a first metering pump.

Optionally TPU particles are dried by a second dryer so that the moisture content is <NUM> ppm or below, and the TPU pellets are melted by a second extruder. The melting temperature of the second extruder is <NUM>-<NUM>. Optionally themelting temperature of the second extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the high-airtightness TPU layer <NUM> is made through a second metering pump.

Optionally TPU particles are dried by a third dryer so that the moisture content is <NUM> ppm or below, and the TPU pellets are melted by a third extruder. The melting temperature of the third extruder is <NUM>-<NUM>. Optionally themelting temperature of the third extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the second high-resilience TPU layer <NUM> is made through a third metering pump.

Optionally cooling is performed by using a first coating wheel to form a film, the high-airtightness TPU layer <NUM> is disposed on the second high-resilience TPU layer <NUM>, and the first high-resilience TPU layer <NUM> is disposed on the high-airtightness TPU layer <NUM>. The thickness composite ratio of the first high-resilience TPU layer <NUM> to the high-airtightness TPU layer <NUM> to the second high-resilience TPU layer <NUM> is <NUM>:<NUM>:<NUM>. Optionally the speed of the first coating wheel is <NUM>/min, so that the ball bladder layer <NUM> with a total thickness of <NUM> is made. The thickness of the first high-resilience TPU layer <NUM> may be <NUM>, the thickness of the high-airtightness TPU layer <NUM> may be <NUM>, and the thickness of the second high-resilience TPU layer <NUM> may be <NUM>. The test data is as follows:.

Referring to <FIG> and <FIG> together, with reference to step S42, TPU yarn is disposed to cover the ball bladder layer <NUM> to form a yarn layer <NUM>. In an embodiment, the TPU yarn is wound to cover the ball bladder layer <NUM> to form the yarn layer <NUM>. Referring to the following comparison diagram of breaking strength at <NUM>% elongation, the diagram shows the comparison between the conventional nylon (NYLON <NUM>220D) yarn and the TPU yarn (HT-F 210D) of the present invention. Obviously, the breaking strength of the TPU yarn (HT-F 210D) of the present invention in each tensile test is higher than that of the conventional nylon (NYLON <NUM>220D) yarn. In addition, the breaking strength each time is average.

Referring to <FIG>, <FIG> and <FIG>, with reference to step S43, a surface layer <NUM> is made by using a TPU material. In an embodiment, the step of making the surface layer <NUM> includes a step of making an outer surface layer <NUM>, a foamed latex layer <NUM> and an unfoamed latex layer <NUM>. TPU particles with the Shore hardness of <NUM>-90A and the melting point of <NUM>-<NUM> are dried with a fourth dryer so that the moisture content is <NUM> ppm or below. The TPU pellets are melted by a fourth extruder. The melting temperature of the fourth extruder is <NUM>-<NUM>. Optionally the melting temperature of the fourth extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the outer surface layer <NUM> is made through a fourth metering pump.

Optionally TPU particles with the Shore hardness of <NUM>-85A and the melting point of <NUM>-<NUM> are dried with a fifth dryer so that the moisture content is <NUM> ppm or below. The TPU pellets are melted by a fifth extruder, and <NUM>-<NUM>% of a microsphere foaming agent is added. The melting temperature of the fifth extruder is <NUM>-<NUM>. Optionally the melting temperature of the fifth extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the foamed latex layer <NUM> is made through a fifth metering pump.

Optionally TPU particles with the Shore hardness of <NUM>-85A and the melting point of <NUM>-<NUM> are dried with a sixth dryer so that the moisture content is <NUM> ppm or below. The TPU pellets are melted by a sixth extruder. The melting temperature of the sixth extruder is <NUM>-<NUM>. Optionally the melting temperature of the sixth extruder is set to <NUM>, <NUM> and <NUM> in sequence. The DIE temperature is <NUM>, and the unfoamed latex layer <NUM> is made through a sixth metering pump.

In an embodiment, cooling is performed by using a second coating wheel to form a film, the foamed latex layer <NUM> is disposed on the unfoamed latex layer <NUM>, and the outer surface layer <NUM> is disposed on the foamed latex layer <NUM>. The thickness composite ratio of the outer surface layer to the foamed latex layer to the unfoamed latex layer is <NUM>:<NUM>:<NUM>. In an embodiment, the speed of the second coating wheel is <NUM>/min, so that the surface layer <NUM> with a total thickness of <NUM> is made. The thickness of the outer surface layer <NUM> may be <NUM>, the thickness of the foamed latex layer <NUM> may be <NUM>, and the thickness of the unfoamed latex layer <NUM> may be <NUM>. In an embodiment, the thickness of the outer surface layer <NUM> is <NUM>-<NUM>, the thickness of the foamed latex layer <NUM> is <NUM>-<NUM>, and the thickness of the unfoamed latex layer <NUM> is <NUM>-<NUM>.

Referring to <FIG> and <FIG>, with reference to step S44, the surface layer <NUM> is disposed to cover the yarn layer <NUM> and subjected to hot-working treatment. In an embodiment, by using the hot-working treatment, the yarn layer <NUM> may bond the ball bladder layer <NUM> and the surface layer <NUM> by melting.

Optionally the manufacturing method of the present invention further includes a step of transferring a pattern by pressing, which uses a cold mold to transfer the pattern to the outer surface layer <NUM>.

The manufacturing method of the TPU ball structure <NUM> of the present invention uses the TPU material only, which satisfies the requirement for environmental protection and is recyclable. The above manufacturing method does not need to use any solvent so as to avoid harming the environment. In addition, the layers of the TPU ball structure <NUM> of the present invention are made of the same TPU material, and there is no need to use an adhesive to bond the layers. According to the manufacturing method of the TPU ball structure <NUM> of the present invention, the layers are bonded by melting. Therefore, the peeling strength between the layers can be increased, so that the overall peeling strength of the TPU ball structure <NUM> of the present invention can be increased.

Claim 1:
A TPU ball structure, comprising:
a ball bladder layer, made of a thermoplastic polyurethane (TPU) material;
a yarn layer, made of a TPU material and disposed to cover the ball bladder layer; and
a surface layer, made of a TPU material and disposed to cover the yarn layer,
wherein
- the surface layer comprises an outer surface layer and a latex layer,
and wherein the latex layer comprises a foamed latex layer and an unfoamed latex layer, the foamed latex layer is disposed on the unfoamed latex layer, and the outer surface layer is disposed on the foamed latex layer, the thickness composite ratio of the outer surface layer to the foamed latex layer to the unfoamed latex layer is <NUM>:<NUM>:<NUM>;
and/or
- the ball bladder layer comprises a first high-resilience TPU layer, a high-airtightness TPU layer and a second high-resilience TPU layer, the high-airtightness TPU layer is disposed on the second high-resilience TPU layer, and the first high-resilience TPU layer is disposed on the high-airtightness TPU layer, the thickness composite ratio of the first high-resilience TPU layer to the high-airtightness TPU layer to the second high-resilience TPU layer is <NUM>:<NUM>:<NUM>.