Solid ball manufacturing method

Abstract

The invention relates to the technical field of sports balls, and particularly discloses a solid ball manufacturing method which is simple in process, few in working procedures and capable of shortening the ball production period, improving the production efficiency and reducing the production cost, and then a solid ball which is good in elasticity and does not need to be inflated is manufactured. The manufacturing method of the solid ball comprises the following steps that S1, elastic plastic beads are fed into a foaming forming mold to be heated and foamed, and the elastic plastic beads are exploded in the foaming forming mold to form a spherical inner container; s2, cooling and taking out the foamed spherical liner; s3, an elastic plastic material is fed into an injection molding machine to be subjected to injection molding to form hemispherical leather in a preset shape; s4, cooling and taking out the semi-spherical leather after injection molding; and S5, the surface of the spherical inner container is coated with glue, two pieces of hemispherical leather capable of being spliced into a hollow spherical structure are pressed on the surface of the spherical inner container, and the hemispherical leather and the spherical inner container are bonded.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of sports balls, in particular to a solid ball manufacturing method. BACKGROUND

[0002] At present, the inflatable balls such as basketball, football and rugby on the market generally have an inner container arranged in a spherical outer skin and a limiting structure for limiting the inner container in a specific position in the outer skin. The inner container is inflated to make the whole ball expand into a spherical structure, so as to obtain a rebounding force that enables the ball to rebound after being hit by an external object. However, during the use of the inflatable ball, with the extension of the use time, the one-way inflation valve on the inner container passing through the limiting structure and the spherical outer shell is prone to slow air leakage, which causes the ball to deform and deflate, the elasticity of the ball decreases, and further affects the user's use experience and training effect. Therefore, it is necessary to provide a charging tool and frequently inflate the ball, which causes inconvenience in the use of the ball. In addition, the production process of the inflatable ball includes a middle tire process, a rubber outer skin process, a skin piece process and a forming process. The middle tire process includes refining, opening, sheeting, skin cutting, forming, vulcanization, ball extraction, inflation inspection, winding and other operations. The rubber outer skin process includes refining, opening, skin pasting, vulcanization, inflation, gluing, drying and other operations. The skin piece process includes cutting, edge trimming, stamping, gluing, drying and other operations. The forming process includes manual skin pasting, shaping, appearance inspection, air leakage inspection, finished product manual packaging and other operations. The production process of the inflatable ball is complex and has many processes, which makes the production cycle of the inflatable ball long and the production efficiency low. The number of equipment involved in the production process and the amount of manual operation required are large, which makes the production cost high and difficult to improve the market competitiveness of the product. SUMMARY

[0003] Therefore, it is necessary to provide a solid ball manufacturing method to solve the above problems. The solid ball manufacturing method has simple process and fewer processes, which can shorten the production cycle of the ball, improve the production efficiency and reduce the production cost, and further manufacture a solid ball with good elasticity and without the need for inflation.

[0004] A solid ball manufacturing method, comprising the following steps:

[0005] S1, sending elastic plastic beads into a foaming forming mold to heat and foam, so that the elastic plastic beads are explosively formed into a spherical inner container in the foaming forming mold;

[0006] S2, cooling and taking out the foamed spherical inner container;

[0007] S3, sending an elastic plastic material into an injection molding machine to be injection molded into a half-spherical skin with a preset shape;

[0008] S4, cooling and taking out the injection-molded half-spherical skin;

[0009] S5, glue the surface of the spherical inner container, and press the two half-sphere skins that can be combined into a hollow spherical structure on the surface of the spherical inner container to make the half-sphere skins adhere to the spherical inner container.

[0010] In one of the embodiments, before step S1, it further includes:

[0011] S01, dry the elastic plastic beads at a temperature of 50-80℃ for 4-6h to remove the moisture and volatile substances on the surface of the elastic plastic beads.

[0012] In one of the embodiments, step S1 includes:

[0013] S11, send the elastic plastic beads into the foaming cavity of the foaming forming mold through the air pressure conveying system, and the shape of the foaming cavity is adapted to the shape of the spherical inner container;

[0014] S12, heat the foaming forming mold through steam to make the elastic plastic beads foaming form under the preset conditions.

[0015] In one of the embodiments, in step S12, the foaming temperature of the elastic plastic beads is 125-145℃, the steam pressure is 0.1-0.3Mpa, and the foaming time is 6-10min.

[0016] In one of the embodiments, step S2 includes:

[0017] S21, close the steam heating system, and cool the foaming forming mold to 60℃ for 2-5min;

[0018] S22, open the foaming forming mold and take out the foaming formed spherical inner container, and detect the size and foaming quality of the spherical inner container.

[0019] In one of the embodiments, the density of the elastic plastic material is 0.8-1.3g / cm 3 , and the melt index under the condition of 190℃ and 2.16kg weight is 7-25g / 10min.

[0020] In one of the embodiments, step S3 includes:

[0021] S31, dry the elastic plastic material at a temperature of 80-85℃ for 2-3h to remove the moisture and volatile substances on the surface of the elastic plastic material;

[0022] S32, place the dried elastic plastic material into the injection molding machine to be injection molded into the half-sphere skin, and the injection molding temperature is 170-200℃, the injection molding pressure is 50-80bar, the injection speed is 40-70mm / s, and the injection molding time is 3-5s.

[0023] In one of the embodiments, the step S4 comprises:

[0024] S41, cooling the mold of the injection molding machine to 40-60 DEG C;

[0025] S42, using a manipulator to take the hemispherical skin out of the mold of the injection molding machine;

[0026] S43, detecting the appearance of the hemispherical skin.

[0027] In one of the embodiments, the step S5 comprises:

[0028] S51, using a conveyor belt to convey the qualified spherical inner container to a rubber coating station, and using an automatic rubber coating device to coat the surface of the spherical inner container;

[0029] S52, conveying the rubber coated spherical inner container to a pressing station, and using an automatic pressing device to press and press the hemispherical skin to the surface of the spherical inner container; the holding pressure temperature is 80-100 DEG C, the holding pressure is 3-5 MPa, and the holding time is 2-3 min.

[0030] In one of the embodiments, the step S5 further comprises:

[0031] S6, conveying the pressed spherical body to a pad printing station, and using a pad printing device to print a pattern on the surface of the spherical body;

[0032] S7, checking the quality of the spherical body, and packaging the qualified products.

[0033] The solid ball manufacturing method of the present application, by explosion forming of elastic plastic beads to obtain a spherical inner container, and injection molding of elastic plastic material to obtain a hemispherical skin, after coating the surface of the spherical inner container, the two hemispherical skins are pressed on the surface of the spherical inner container, that is, the solid ball is obtained. Compared with the production process of the inflatable ball, the number of processes and steps involved is reduced, the production cycle is greatly shortened, the production efficiency of the solid ball is improved, the number of equipment involved in the production process and the amount of manual work are reduced, thereby reducing the production cost of the solid ball, which is conducive to improving the market competitiveness of the product. The spherical inner container obtained by explosion forming provides good elasticity for the whole solid ball, ensures the effective rebound of the solid ball, and replaces the hollow inner container of the traditional inflatable ball, which does not need to be inflated to ensure the continuous and effective use of the solid ball, and improves the convenience of the ball use. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 The structure diagram of the solid ball manufactured by the solid ball manufacturing method in one embodiment of the present application;

[0035] Figure 2Fig. 1 is a schematic view of a cross-sectional structure of a solid ball manufactured by a solid ball manufacturing method according to an embodiment of the present application;

[0036] Figure 3 Fig. 2 is a flow chart of a solid ball manufacturing method according to an embodiment of the present application;

[0037] Figure 4 Fig. 3 is a schematic view of a system structure for implementing the solid ball manufacturing method according to an embodiment of the present application. DETAILED DESCRIPTION

[0038] In order to make the above objectives, features and advantages of the present application more apparent, specific embodiments of the present application will be described in detail below with reference to the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present application. It will be apparent, however, to one skilled in the art that the present application can be practiced in a variety of ways beyond the specific embodiments described herein without departing from the spirit of the present application, and that the present application is not limited to the specific embodiments disclosed below.

[0039] The present application discloses a solid ball manufacturing method, and a structure of a solid ball manufactured by the solid ball manufacturing method is shown in Fig. 1. Figures 1-2 Specifically, the solid ball comprises a spherical inner container 100, a first adhesive layer 200 coated on a surface of the spherical inner container 100, and two half-spherical skins 300 oppositely arranged. The two half-spherical skins 300 can be combined into a hollow spherical structure, and form a closed spherical inner cavity in the hollow spherical structure. The spherical inner container 100 is accommodated in the spherical inner cavity, and the first adhesive layer 200 is adhered to inner surfaces of the half-spherical skins 300. A second adhesive layer 400 is arranged at a joint of the two half-spherical skins 300. In the embodiment, the first adhesive layer 200 is obtained by coating glue on the surface of the spherical inner container 100, and then solidifying the glue after the spherical inner container 100 and the half-spherical skins 300 are extruded together. The second adhesive layer 400 can be obtained by coating glue on a joint surface of the two half-spherical skins 300, and then solidifying the glue after the two half-spherical skins 300 are extruded. Alternatively, the second adhesive layer 400 can be obtained by coating glue on the surface of the spherical inner container 100, and then solidifying the glue after the glue overflows from the joint of the two half-spherical skins 300 when the spherical inner container 100 and the half-spherical skins 300 are extruded. According to different conditions such as the size of the solid ball and the density of the spherical inner container 100, the solid ball can be used as a basketball, a football or a rugby ball. In the embodiment, the diameter of the spherical inner container 100 is 75-250 mm, the thickness of the first adhesive layer 200 is 0.1-0.3 mm, the thickness of the second adhesive layer 400 is 0.1-0.3 mm, and the thickness of the half-spherical skin 300 is 1-5 mm.

[0040] Fig. 2 is a flow chart of a solid ball manufacturing method according to an embodiment of the present application; Figure 4The system for implementing the solid ball manufacturing method of the present application comprises a liner forming unit, a skin forming unit, a pressing and post-processing unit, wherein the liner forming unit comprises a foaming forming die 10, a temperature control module for heating or cooling the foaming forming die 10, and a pressure control module for controlling the internal pressure of the foaming forming die 10; the skin forming unit comprises an injection molding machine 20; the pressing and post-processing unit comprises a conveying belt structure for conveying the spherical liner 100, a glue coating device 30 for coating glue on the spherical liner 100, a pressing device 40 for pressing the half-skin 300 on the surface of the spherical liner 100, and a pad printing device 50 for printing patterns on the surface of the spherical liner 100. The system further comprises a controller electrically connected to the electrical devices of each unit, a power supply for providing power supply for the entire system, and a control panel for adjusting the operating parameters of the system.

[0041] Further in combination with Figures 1-4 The solid ball manufacturing method of the present embodiment comprises the following steps:

[0042] S1, the elastic plastic beads are sent into the foaming forming die 10 to be heated and foamed, so that the elastic plastic beads are explosively formed into a spherical liner 100 in the foaming forming die 10.

[0043] In the present embodiment, after the elastic plastic beads are foamed in the foaming forming die 10, the elastic plastic beads melt and form a whole piece of glue during the heating process, and then the glue is explosively formed, the volume is expanded, and the spherical liner 100 is formed in the foaming forming die 10. Since the spherical liner 100 is explosively formed by the elastic plastic beads after foaming, the spherical liner 100 is a loose porous structure as a whole, and the spherical liner 100 has a large number of pores inside. In this way, on the one hand, the elastic plastic bead material itself will give the spherical liner 100 the characteristic of high resilience, and on the other hand, the existence of pores can reduce the weight of the whole solid ball, realizing the lightweight of the solid ball. The porous structure also allows the material to be reversibly compressed on a large scale (pores are flattened or gas is compressed) under external force, and after the external force is removed, the original state is restored by relying on the elasticity of the polymer molecular chain. The pores will concentrate the stress on the pore walls and ligaments (polymer skeleton between pores), which can avoid permanent deformation or rupture caused by local stress concentration on the spherical liner 100, so as to prolong the service life of the spherical liner 100.

[0044] The elastic plastic beads can be selected from one of TPU (Thermoplastic Polyurethane), TPE (Thermoplastic Elastomer), TPEE (Thermoplastic Polyester Elastomer) and EVA (Ethylene-Vinyl Acetate). In this embodiment, the elastic plastic beads are TPU micro-foamed particles. The TPU micro-foamed particles are TPU particles filled with micro-pores of 1-100 μm in diameter by physical foaming or chemical foaming. In the physical foaming, supercritical fluid technology is used to inject supercritical carbon dioxide or nitrogen into the molten TPU material under high temperature and high pressure, so that the supercritical fluid is fully dissolved, and then the dissolved gas is expanded instantaneously by rapid pressure relief and temperature reduction, so that a large number of tiny bubble nuclei are formed in the TPU matrix and grow and solidify to form uniformly distributed closed micro-pores. In the chemical foaming, a chemical foaming agent is added to the TPU material, and the chemical foaming agent is decomposed to generate gas (such as nitrogen, carbon dioxide) when heated to form pores. Preferably, in this embodiment, the TPU particles are physically foamed and cut or granulated to form TPU micro-foamed particles. By selecting TPU micro-foamed particles to prepare the spherical liner 100, the micro-porous structure in the TPU micro-foamed particles gives the TPU micro-foamed particles extremely high energy absorption efficiency. In the process of explosive forming, the numerous tiny closed pores dissipate a large amount of impact energy through elastic deformation, bending or even collapse of the pore walls, which can reduce the peak pressure transmitted to the foaming mold 10, reduce the wear of the foaming mold 10, and thus prolong the service life of the mold. In addition, the buffering effect of the micro-porous structure can make the forming process more controllable, reduce the tearing, wrinkling or uneven forming caused by excessive impact; the combination of TPU material and micro-pores makes the TPU micro-foamed particles deform and impact the inner wall of the mold under the impact of the shock wave during explosive forming, and the high resilience of the TPU micro-foamed particles helps the material closely fit the mold surface, reduces the size deviation caused by rebound, improves the forming precision and the ability to reproduce the details of the mold. The TPU micro-foamed particles have good resilience, which can make the residual stress in the material after foaming lower, the dimensional stability of the spherical liner 100 better, and the spherical liner 100 less likely to deform or crack, thereby improving the quality of the spherical liner 100. In this embodiment, the particle size of the TPU micro-foamed particles is 3-5 mm.

[0045] In this embodiment, before step S1, the following steps are further included:

[0046] S01, dry the elastic plastic beads at a temperature of 50-80℃ for 4-6h to remove the moisture and volatile substances on the surface of the elastic plastic beads, so as to avoid the interference of the moisture or volatile substances attached to the surface of the elastic plastic beads during storage or transportation on the foaming operation of the elastic plastic beads.

[0047] Step S1 includes:

[0048] S11, the elastic plastic beads are sent into the foaming chamber of the foaming forming mold 10 through the pneumatic conveying system, the shape of the foaming chamber is adapted to the shape of the spherical liner 100. In the embodiment, the stock bin for storing the elastic plastic beads is communicated with the feeding port of the pneumatic conveying system through the first feeding pipe, and the foaming chamber of the foaming forming mold 10 is communicated with the discharging port of the pneumatic conveying system through the second feeding pipe, so that the elastic plastic beads are blown into the foaming chamber under the action of the pneumatic conveying system. A valve that can be opened and closed is arranged at the entrance of the foaming chamber, which is used to open to provide an elastic plastic bead feeding channel when the elastic plastic beads are fed, and is also used to close to separate the foaming chamber from the first feeding pipe and the stock bin during the foaming operation, so that the stable foaming pressure is maintained in the foaming chamber. In the embodiment, the inner surface of the foaming chamber is spherical, and the surface of the valve adjacent to the foaming chamber is also spherical when the valve is closed. The valve and the inner surface of the foaming chamber jointly form a complete spherical structure, so that the foamed elastic plastic beads fill the inner wall of the entire foaming chamber after foaming and explosion forming, thereby forming the spherical liner 100.

[0049] S12, the foaming forming mold 10 is heated by steam to make the elastic plastic beads foaming and forming under the preset conditions. Preferably, in step S12, the foaming temperature of the elastic plastic beads is 125-145℃, the steam pressure is 0.1-0.3Mpa, and the foaming time is 6-10min.

[0050] In the embodiment, the temperature control unit realizes uniform heating of the elastic plastic beads by injecting high-temperature steam into the foaming chamber of the foaming forming mold 10, so that the high-temperature steam exchanges heat with the elastic plastic beads, thereby improving the foaming effect.

[0051] In the process of processing the spherical inner liner 100, the added elastic plastic beads are TPU micro-foaming particles, and the elastic plastic beads have a large number of micro-holes, and the density is greatly reduced. Before explosion forming, the elastic plastic beads are placed in a constant temperature and humidity environment for storage, so that air penetrates into the inside of the elastic plastic beads to balance the internal and external pressure and prepare for secondary foaming. When the elastic plastic beads are blown into the foaming chamber of the foaming forming mold 10, the temperature control module quickly injects high-pressure steam (125-145°C) into the foaming chamber through the air holes of the foaming forming mold 10. The high-pressure steam will diffuse in the micro-hole gap inside the elastic plastic beads, and the steam heat will soften the surface layer of the elastic plastic beads. When the mold instantaneously releases the internal pressure (such as opening the exhaust valve or pressure relief port, or when vacuumizing), the high-pressure steam in the foaming chamber rapidly escapes, the pressure drops sharply, and the high-pressure gas inside the elastic plastic beads loses external constraint, pushing the softened polymer (softened elastic plastic beads) to expand rapidly, forming a uniform foam structure, completely filling the mold details, and the elastic plastic beads are extruded and welded due to the expansion force. Finally, the spherical inner liner 100 is obtained which is adapted to the contour shape in the foaming chamber.

[0052] S2, cooling and taking out the foamed spherical inner liner 100.

[0053] Step S2 includes:

[0054] S21, turn off the steam heating system, and cool the foaming forming mold 10 to 60°C, and the cooling time lasts for 2-5 min.

[0055] S22, open the foaming forming mold 10 and take out the foamed spherical inner liner 100, and detect the size and foaming quality of the spherical inner liner 100.

[0056] Specifically, in the present embodiment, the temperature control unit passes cooling water into the cooling waterway surrounding the foaming forming mold, the foamed elastic plastic beads are quickly solidified, and the spherical inner liner 100 is formed. The spherical inner liner 100 can be taken out by a mechanical hand or manually, and the true roundness of the spherical inner liner 100 is detected by a true roundness detection device, the size of the spherical inner liner 100 is detected by an infrared sensor, the weight of the spherical inner liner 100 is detected by a weighing instrument, the rebound rate of the spherical inner liner 100 is detected by a falling ball rebound tester, and the density of the spherical inner liner 100 can also be detected by a density detection device. The qualified products are sent to the conveyor belt structure, and the unqualified products are recycled.

[0057] S3, the elastic plastic material is sent into the injection molding machine 20 to be injection molded into a half-sphere skin 300 of a preset shape.

[0058] In this embodiment, the elastic plastic material includes the following components by weight: SEBS 20-45 parts; softening oil 45-65 parts; PP material 20-45 parts; antioxidant 0.06-0.16 parts; stabilizer 0.03-0.08 parts; light stabilizer 0.1-0.5 parts; toner 0.5-1.5 parts. Among them, SEBS (styrene-ethylene-butylene-styrene block copolymer) is a high-performance thermoplastic elastomer (TPE), which is used as a key modified additive in ball skin materials (such as basketball, football, volleyball), mainly for improving flexibility, low temperature resistance and anti-aging performance. Softening oil is a saturated hydrocarbon or a mixture of multiple saturated hydrocarbons, for example, the softening oil includes at least one of linear alkanes, branched alkanes and cycloalkanes; PP is a polypropylene material; the antioxidant is at least one of hindered phenolic antioxidants and phosphite antioxidants; the stabilizer is a phosphite or metal soap stabilizer (such as calcium-zinc (Ca / Zn), barium-zinc (Ba / Zn) composite), and the light stabilizer is a benzotriazole or benzophenone or hindered amine (HALS) light stabilizer. In this embodiment, the stabilizer is compounded with the antioxidant, and the addition ratio of the stabilizer to the antioxidant is 1:2, which is used to prevent the ball skin from aging during use, and the light stabilizer is used to prevent aging in the external environment and prevent material cracking. The toner is an additive used to identify the color of the ball, and different colored toners can be added according to the user's needs to make the appearance of the solid ball present a predetermined color. The above ball skin material (SEBS, PP, softening oil, antioxidant, stabilizer, light stabilizer and toner) is mixed uniformly according to a specific weight ratio, then melted and extruded at high temperature to obtain an elastic plastic material for manufacturing the half ball skin 300.

[0059] In this embodiment, the above material is used as the raw material of the ball skin material, which realizes the modification of the ball skin raw material, so that the ball skin not only has better mechanical properties such as wear resistance, aging resistance and tear resistance, but also reduces the production cost. The ball skin made of the ball skin material can improve the elasticity, wear resistance and aging resistance of the ball, meet the market demand for high-quality sports products, and has important application value and broad market prospect.

[0060] In other embodiments, the elastic plastic material can also be made of one of the following materials: TPU (Thermoplastic Polyurethane), TPE (Thermoplastic Elastomer), PU (Polyurethane), PE (Polyethylene), POE (Polyolefin Elastomer), TPEE (Thermoplastic Polyester Elastomer), EVA (Ethylene-Vinyl Acetate), PEBA (Polyether Block Amide), and OBC (Olefin Block Copolymer).

[0061] Step S3 includes:

[0062] S31, dry the elastic plastic material at a temperature of 80-85°C for 2-3 hours to remove the moisture and volatile substances on the surface of the elastic plastic material, so as to avoid the influence of the moisture and volatile substances on the ball skin injection operation. In this embodiment, the density of the elastic plastic material is 0.8-1.3 g / cm 3 , and the melt index is 7-25 g / 10 min (the melt index is obtained under the condition that the total weight (including the self-weight of the piston) applied on the piston is 2.16 kg at 190°C), that is, the melt index under the condition of 190°C and 2.16 kg weight is 7-25 g / 10 min.

[0063] S32, place the dried elastic plastic material in the injection molding machine 20 to be injection molded into a half ball skin 300, the injection molding temperature is 170-200°C, the injection molding pressure is 50-80 bar, the injection speed is 40-70 mm / s, and the injection molding time is 3-5 s.

[0064] S4, cool and take out the injection-molded half ball skin 300.

[0065] Step S4 includes:

[0066] S41, cool the mold of the injection molding machine 20 to 40-60°C.

[0067] S42, use a mechanical hand to take out the half ball skin 300 from the mold of the injection molding machine 20.

[0068] S43, detect the appearance of the half ball skin 300.

[0069] It should be noted that, in the embodiment, before the formal injection molding operation, one or several products need to be pre-injected to verify the product quality before mass production. Specifically, the injection molding machine 20 and the mold are first checked, and the mold is installed in the preset position in the injection molding machine 20. Then, the injection molding parameters are adjusted, that is, the injection molding temperature is 170-200°C, the injection molding pressure is 50-80 bar, the injection speed is 40-70 mm / s, and the injection molding time is 3-5 s. After the equipment debugging is completed, the first hemispherical skin 300 is produced, the mold is heated, and the upper and lower molds of the mold are closed, so that the elastic plastic material after heating is softened and shaped into a hemispherical skin 300 that is adapted to the shape of the closed mold cavity. After the hemispherical skin 300 cools down, it is taken out, and the quality of the skin is detected, such as whether the hemispherical skin 300 is wrinkled or complete. After the first product is qualified, batch injection molding production is carried out, and after the hemispherical skin 300 is injected, a mechanical hand is used to automatically take out the hemispherical skin 300. The mechanical hand can be a commercially available four-axis mechanical hand or a six-axis mechanical hand, and the mechanical hand is electrically connected with the controller of the injection molding machine 20, and the hemispherical skin 300 is taken out from the mold cavity when the injection molding machine 20 is opened. In addition, in the embodiment, AOI (Automated Optical Inspection) appearance detection is used to monitor the appearance quality of the hemispherical skin 300. AOI appearance detection is an industrial automation technology based on machine vision, which collects product images through high-resolution industrial cameras (such as CMOS / CCD) combined with LED ring light sources, coaxial light sources or structured light, and judges the defects of the product through image processing (such as template matching, feature extraction and deep learning, etc.), so as to realize the automatic detection of the appearance quality of the product.

[0070] S5, glue is coated on the surface of the spherical inner container 100, and two hemispherical skins 300 that can be split into a hollow spherical structure are pressed together on the surface of the spherical inner container 100, so that the hemispherical skins 300 are bonded to the spherical inner container 100.

[0071] Step S5 includes:

[0072] S51, adopt the conveying belt to convey the detection qualified spherical inner container 100 to the rubberizing work station, and adopt the automatic rubberizing equipment 30 to rubberize the surface of the spherical inner container 100. In the embodiment, the conveying belt is provided with a jig for loading the spherical inner container 100, the jig has a plurality of support points in point contact with the spherical inner container 100, which can reduce the shielding of the spherical inner container 100 while supporting the spherical inner container 100. The automatic rubberizing equipment 30 can attach the glue liquid to the surface of the spherical inner container 100 by point coating or spraying. Preferably, the automatic rubberizing equipment 30 attaches the glue liquid to the surface of the spherical inner container 100 by spraying, so that the thickness of the glue liquid on the surface of the spherical inner container 100 is uniform. The glue on the spherical inner container 100 needs to meet that the thickness of the glue (i.e. the thickness of the first adhesive layer 200) is 0.1-0.3mm, the finished product ball obtained by gluing the spherical inner container 100 and the ball skin does not come off under the condition of 10000 impacts, and the peeling force is greater than 3kg. In the embodiment, the glue is polyurethane adhesive (PU glue), of course, other commercially available glues that can meet the adhesive properties of the first adhesive layer 200 and the second adhesive layer 400 can also be selected, which will not be described here.

[0073] S52, convey the rubberized spherical inner container 100 to the pressing work station, and adopt the automatic pressing equipment 40 to grab and press the half ball skin 300 to the surface of the spherical inner container 100; the holding temperature is 80-100℃, the holding pressure is 3-5MPa, and the holding time is 2-3min. The automatic pressing equipment 40 includes two pressing mold plates arranged opposite to each other, the pressing mold plates are provided with half spherical grooves, and the half spherical grooves are provided with vacuum suction holes, so that the two pressing mold plates each suction a half ball skin 300, during the pressing operation, the two pressing mold plates are close to each other and the two half ball skins 300 are attached to the surface of the spherical inner container 100, and the holding time is a period of time, so that the half ball skin 300 is firmly bonded with the spherical inner container 100, i.e. a complete ball is obtained. Of course, in other embodiments, the pressing equipment 40 can also be a common pressing machine with vacuum suction function, which will not be described here.

[0074] It should be noted that in the embodiment, the shapes of the two half ball skins 300 can be completely the same or different, when the shapes of the two half ball skins 300 are the same, only one mold needs to be arranged in the injection molding machine 20 to process all the half ball skins 300. When the shapes of the two half ball skins 300 are different, the mold needs to be replaced to process half ball skins 300 of different shapes, and correspondingly, during the pressing operation, the groove shape of the pressing mold plate is adapted to the shape of the half ball skin 300 to stably support the half ball skin 300, facilitating positioning of the half ball skin 300.

[0075] After step S5, it further includes:

[0076] S6, the pressed sphere is transported to a pad printing station, and a pad printing device 50 is used to print a pattern on the surface of the sphere, so that the solid sphere has a predetermined appearance.

[0077] S7, the quality of the sphere is checked, and the qualified products are packaged.

[0078] Specifically, the quality of the sphere is tested. When the sphere is used as a basketball, the aging resistance test includes: no cracks, discoloration and deformation under the condition of 60℃ for 72h, 70℃ temperature, 90% RH humidity, and 7 days of test time. In the yellowing resistance test chamber, the sphere has no color change and no cracking phenomenon under simulated sunlight. The impact resistance test (GB / T14625.3) includes: 8000 times of impact, the sphere has an expansion rate of less than 1.03% after impact, a deformation value of less than 3mm after impact, and no rupture, implosion, delamination and deformation after impact. When the sphere is used as a football (according to the standard of FIFA QUALITY PRO), the maximum deformation value is less than 1.5%; the rebound height test: 135-155cm at 20℃, and the minimum rebound height is 125cm at 5℃, wherein the difference between the highest value and the lowest value of the rebound of three test balls is at most 10cm; impact test (impact on a steel plate at an angle of 30°±2 with a horizontal line at an outlet speed of 50km / h±1, 2000 times): the circumference change is at most 1cm, the deformation value is at most 1.5%, and the joint and valve are not damaged. It can be seen that the quality of the solid sphere manufactured by the above method can meet the use requirements of professional sports balls.

[0079] The above-mentioned solid sphere manufacturing method obtains a spherical inner container 100 by explosion forming of elastic plastic beads, and obtains a hemispherical skin 300 by injection molding of elastic plastic material. After gluing the surface of the spherical inner container 100, two hemispherical skins 300 are pressed on the surface of the spherical inner container 100, and a solid sphere is obtained. Compared with the manufacturing process of the inflatable ball, the number of process flows and steps involved is reduced, the production cycle is greatly shortened, the production efficiency of the solid sphere is improved, the number of equipment involved in the production process and the amount of manual work are reduced, thereby reducing the production cost of the solid sphere, and improving the market competitiveness of the product. The spherical inner container 100 obtained by explosion forming provides good elasticity for the entire solid sphere, ensures effective rebound of the solid sphere, and replaces the hollow inner container of the traditional inflatable ball. The solid sphere can be used continuously and effectively without inflation, improving the convenience of using the sphere.

[0080] The technical features of the above-mentioned embodiments can be combined arbitrarily. In order to make the description simple, all possible combinations of the technical features in the above-mentioned embodiments are not described, however, as long as the combinations of the technical features do not exist contradictory, they should be considered as the scope of the present disclosure.

[0081] The above embodiments only express several implementation manners of the present application, which are described in a more specific and detailed manner, but cannot be understood as a limitation on the patent scope of the present application. It should be noted that, for ordinary skilled persons in the art, several modifications and improvements can be made without departing from the concept of the present application, which all belong to the protection scope of the present application. Therefore, the protection scope of the patent of the present application should be subject to the appended claims.

Claims

1. A method for manufacturing a solid ball, characterized in that: The following steps are involved: S1, feeding elastic plastic beads into a foaming mold to heat and foam, so that the elastic plastic beads are explosively formed into a spherical inner liner in the foaming mold; S2, cooling and taking out the foamed spherical liner; S3, feeding the elastic plastic material into an injection molding machine and injection molding the elastic plastic material into a hemispherical skin of a preset shape; S4, cooling and removing the hemisphere skin after injection molding; S5. Apply glue on the surface of the spherical inner liner, and press two hemispherical skins that can be assembled into a hollow spherical structure onto the surface of the spherical inner liner to bond the hemispherical skins to the spherical inner liner.

2. The method for manufacturing a solid ball according to claim 1, wherein: Before step S1, the method further includes: S01. Dry the elastic plastic beads at 50-80° C. for 4-6 hours to remove moisture and volatile substances on the surface of the elastic plastic beads.

3. The method for manufacturing a solid ball according to claim 1, wherein: Step S1 includes: S11, delivering the elastic plastic beads into the foaming chamber of the foaming molding die through the pneumatic conveying system, wherein the shape of the foaming chamber is adapted to the shape of the spherical liner; S12, heating the foaming mold by steam so that the elastic plastic beads are foamed under preset conditions.

4. The method for manufacturing a solid ball according to claim 3, wherein: In step S12, the elastic plastic beads are foamed at a temperature of 125-145°C, a steam pressure of 0.1-0.3 MPa, and a foaming time of 6-10 minutes.

5. The method for manufacturing a solid ball according to claim 1, wherein: Step S2 includes: S21, turn off the steam heating system to cool the foaming mold to 60°C for 2-5 minutes; S22, opening the foaming mold and taking out the foamed spherical liner, and inspecting the size and foaming quality of the spherical liner.

6. The method for manufacturing a solid ball according to claim 1, wherein: The density of the elastic plastic material is 0.8-1.3 g / cm 3 The melt index at 190°C and a load of 2.16kg is 7-25g / 10min.

7. The method for manufacturing a solid ball according to claim 1, wherein: The step S3 comprises: S31, drying the elastic plastic material at a temperature of 80-85° C. for 2-3 hours to remove moisture and volatile substances on the surface of the elastic plastic material; S32, placing the dried elastic plastic material in an injection molding machine and injection molding it into the hemispherical skin with a mold, the injection molding temperature is 170-200° C., the injection molding pressure is 50-80 bar, the injection speed is 40-70 mm / s, and the injection molding time is 3-5 s.

8. The method for manufacturing a solid ball according to claim 1, wherein: The step S4 comprises: S41, cooling the injection molding machine mold to 40-60°C; S42, using a robot to remove the hemisphere skin from the injection molding machine mold; S43. Detect the appearance of the hemisphere skin.

9. The method for manufacturing a solid ball according to claim 1, wherein: The step S5 comprises: S51, using a conveyor belt to convey the qualified spherical liner to the gluing station, and using automatic gluing equipment to apply glue to the surface of the spherical liner; S52. The glue-coated spherical liner is transferred to a pressing station, and an automatic pressing device is used to grab and press the hemispherical skin onto the surface of the spherical liner; the pressing temperature is 80-100°C, the pressing pressure is 3-5MPa, and the pressing time is 2-3min.

10. The method for manufacturing a solid ball according to claim 9, wherein: After step S5, the following steps are also included: S6, transporting the pressed sphere to a pad printing station, and using pad printing equipment to print a pattern on the surface of the sphere; S7. Check the quality of the balls and pack the qualified ones.

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