Production method of novel embossed basketball leather

Abstract

The invention relates to the technical field of preparation of basketball leather, and provides a production method of novel embossed basketball leather, which solves the defects of unclear lines and non-three-dimensional lines of a product prepared from basketball leather in the prior art due to the defects of a production process, and comprises the following preparation steps: (1) preparing a base material: the base material is a high-elasticity non-woven fabric; (2) preparing composite slurry, wherein the composite slurry comprises slurry A and slurry B; (3) coating, pre-curing and embossing treatment; (4) compounding a base material with the release paper which is processed in the step (3), has the grains and is provided with the coating, and drying at 120-150 DEG C for 2-5 minutes; and (5) cooling, and stripping the release paper to obtain the novel embossed basketball leather.

Description

Technical Field

[0001] This invention relates to the field of basketball leather preparation technology, and in particular to a novel method for producing embossed basketball leather. Background Technology

[0002] Basketball leather, as a high-performance synthetic leather, must simultaneously meet the stringent requirements of professional sports for wear resistance, impact resistance, high resilience, comfortable feel, and stable grip. Surface embossing is a key process that gives basketball leather a specific texture to enhance friction and tactile feel. The main existing technology for producing embossed basketball leather is: PU wet / dry composite followed by embossing. Specifically, a microporous layer is first formed on the base fabric using a wet process, followed by a dry process to coat the surface layer and then emboss. Embossing often uses high-temperature hot pressing. This manufacturing process is prone to causing the surface resin to age, affecting the product's durability and flexibility. For high-density, high-hardness basketball leather, it can easily result in inconsistent pattern depth and a lack of three-dimensionality. Furthermore, the pattern is prone to fading or even disappearing due to stress rebound during long-term use. Additionally, the use of organic solvents such as dimethylformamide raises concerns about volatile organic compound emissions and residues, making it less environmentally friendly.

[0003] Chinese patent publication number CN120816795A discloses a fully recyclable TPU foamed basketball leather and its preparation method, including a TPU foam film and a TPU film disposed on the upper end of the TPU foam film. The TPU film comprises the following components by weight: 60-80 parts TPU particles, 35-45 parts TPU-modified leather fiber composite material, 15-25 parts hydroxyl-terminated nitrile butadiene rubber, 7-12 parts reinforcing filler, 5-8 parts lubricant, and 6-9 parts antioxidant. This TPU foamed basketball leather is fully recyclable and also possesses excellent wear resistance, flexural strength, aging resistance, tensile strength, impact resistance, and burst resistance. It is convenient to use and has a wide range of applications. However, this patent focuses on improving the environmental friendliness of the material and does not address how to emboss clear textures on the basketball leather. Summary of the Invention

[0004] Therefore, in view of the above problems, the present invention provides a novel method for producing embossed basketball leather, which solves the defects of existing basketball leather, such as unclear and non-three-dimensional textures in the produced products due to defects in the production process.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: a novel method for producing embossed basketball leather, comprising the following preparation steps: (1) Preparation of substrate: The substrate is a highly elastic nonwoven fabric; (2) Preparation of composite slurry: The composite slurry includes slurry A and slurry B; (3) Coating, pre-curing and embossing: The A slurry and the B slurry are coated sequentially on the continuously conveyed release paper to obtain a release paper with a wet mixed coating. Then, the release paper with the mixed coating is pre-cured to obtain a release paper with a plastic surface and a coating. Finally, the texture is pressed out using an embossing roller. (4) The substrate is laminated with the textured coated release paper obtained in step (3), and then dried at 120-150℃ for 2-5 minutes. (5) Cool and peel off the release paper to obtain a new type of embossed basketball leather.

[0006] Furthermore, the A slurry comprises the following raw materials in parts by weight: 100 parts of waterborne polyurethane resin, 5-10 parts of wear-resistant reinforcing particles, 1-3 parts of multifunctional aziridine crosslinking agent, 0.3-0.5 parts of polyether siloxane nonionic wetting agent, 0.1-0.3 parts of defoamer, and 5-20 parts of deionized water. The preparation steps of the A slurry are as follows: waterborne polyurethane resin, polyether silane nonionic wetting agent, defoamer and deionized water are mixed and stirred evenly, then wear-resistant reinforcing particles are added, and the mixture is stirred until it is completely dispersed. Then, multi-tube energy aziridine crosslinking agent is added, stirred evenly and then allowed to stand to defoam for later use. The B slurry comprises the following raw materials in parts by weight: 100 parts solvent-free polyurethane prepolymer, 25-35 parts polyether polyol, 5-8 parts 1,4-butanediol, 1-3 parts deionized water, 0.1-0.5 parts bismuth-zinc composite catalyst, 8-10 parts halogen-free flame retardant, and 1-3 parts foam stabilizer. The preparation steps of the B slurry are as follows: add polyether polyol, 1,4-butanediol, deionized water, bismuth-zinc composite catalyst, halogen-free flame retardant, and foam stabilizer to a mixing tank according to the weight parts mentioned above, stir at 1500-2000 rpm for 1-2 minutes to mix evenly and remove some air bubbles, then add solvent-free polyurethane prepolymer under continuous stirring and a vacuum degree of -0.08-0.09 MPa, and continue stirring for 2-3 minutes to form the B slurry.

[0007] Further: During the pre-curing process in step (3), the reactive components in the B slurry are foamed and initially cross-linked, so that the mixed coating forms a state in which the surface remains plastic and the interior has supporting strength. Then, the texture is imprinted onto the surface of the mixed coating by an embossing roller and initially shaped.

[0008] Furthermore, the pressure of the embossing roller is controlled at 3-12 MPa.

[0009] Further: The specific preparation steps of step (1) of the high-elasticity nonwoven fabric are as follows: S1, using 70-85 parts by weight of polyester short fiber, 15-30 parts by weight of spandex short fiber, and 1-3 parts by weight of antistatic agent as raw materials, the fibers are dispersed evenly by mechanical opening and airflow mixing; S2, the mixed fibers are carded into a web by a carding machine to obtain a fiber web; S3, the fiber web is conveyed to a two-roll hot rolling mill and hot-pressed and bonded under the conditions of roll temperature of 130-155℃ and linear pressure of 20-40 N / mm, so that the fibers melt and bond at the intersection point to form a stable nonwoven fabric substrate with three-dimensional elasticity; S4, the nonwoven fabric after hot rolling is cooled and shaped by a cooling roller, and finally wound up for use, thus obtaining the high-elasticity nonwoven fabric.

[0010] Furthermore: The embossing roller described in step (3) is equipped with a replaceable modular embossing roller set with different textures.

[0011] Furthermore, the waterborne polyurethane resin is an aliphatic waterborne polyurethane dispersion with a bio-based content of not less than 30%.

[0012] Furthermore: the wear-resistant reinforcing particles are a compound of nano-silica modified with silane coupling agent and water-based polyurethane wax paste, wherein the mass ratio of nano-silica modified with silane coupling agent to water-based polyurethane wax paste is 3:1.

[0013] Furthermore, the bio-based raw material is selected from one of the following: plant oil polyols, bio-based polyether polyols, and sugar derivative polyols.

[0014] By adopting the aforementioned technical solution, the beneficial effects of the present invention are as follows: 1. This application places the embossing process beforehand and completes it simultaneously with the coating pre-curing, effectively solving the problems of shallow embossing and easy disappearance of patterns caused by the already cured coating in traditional embossing. At the same time, the use of high-elasticity non-woven fabric as the base material provides the basketball leather with superior overall resilience and cushioning performance.

[0015] 2. The coating uses a water-based A slurry, combined with a specific solvent-free B slurry, resulting in a more environmentally friendly overall formulation. Simultaneously, the aziridine crosslinking agent in the A slurry enhances the wear resistance, hydrolysis resistance, and interfacial adhesion between the surface layer and the B layer. The B slurry is prepared using a vacuum high-speed stirring process, ensuring uniform mixing of the foaming components and minimizing air bubbles. The resulting micro-foamed layer, after curing, is not only lightweight and soft but also serves as an intermediate adhesive layer, forming a strong and tough bond with the A layer and the base fabric through a chemical reaction, thus solving the problem of easy delamination in multilayer composite materials.

[0016] 3. During the pre-curing process, the B slurry is allowed to "foam and initially cross-link," achieving the ideal embossing state of "plastic surface and internal support." This state is crucial for high-quality embossing: surface plasticity ensures that the embossing roller can easily and clearly imprint the pattern; while the initially formed internal support network resists embossing pressure, prevents the pattern from collapsing, and keeps the embossed pattern stable in subsequent processes. This effect overcomes the shortcomings of traditional processes where wet embossing is prone to deformation and dry embossing requires high pressure.

[0017] 4. Precisely control the pressure of the embossing roller within the range of 3-12 MPa. This ensures that the texture is embossed on the coating surface with sufficient depth and clarity to meet the grip requirements of the basketball, while avoiding crushing the internal foam structure or damaging the base fabric due to excessive pressure. This achieves the best balance between texture expression and protection of the substrate. Detailed Implementation

[0018] Example 1

[0019] A novel method for producing embossed basketball leather includes the following preparation steps: (1) Preparation of substrate: The substrate is a high-elasticity nonwoven fabric; the specific preparation steps of the high-elasticity nonwoven fabric are as follows: S1, using 70 parts by weight of polyester short fiber, 30 parts by weight of spandex short fiber, and 1 part by weight of antistatic agent as raw materials, the fibers are dispersed evenly by mechanical opening and airflow mixing; S2, the mixed fibers are carded into a web by a carding machine to obtain a fiber web; S3, the fiber web is conveyed to a two-roll hot rolling mill and hot-pressed and bonded under the conditions of roll temperature of 130℃ and linear pressure of 20 N / mm, so that the fibers melt and bond at the intersection point to form a stable nonwoven fabric substrate with three-dimensional elasticity; S4, the nonwoven fabric after hot rolling is cooled and shaped by a cooling roller, and finally wound up for use, thus obtaining the high-elasticity nonwoven fabric; (2) Preparation of composite slurry: The composite slurry includes slurry A and slurry B; The A slurry comprises the following raw materials in parts by weight: 100 parts of waterborne polyurethane resin, 5 parts of wear-resistant reinforcing particles, 1 part of a multifunctional aziridine crosslinking agent, 0.3 parts of a polyether siloxane nonionic wetting agent, 0.1 parts of defoamer, and 5 parts of deionized water; the waterborne polyurethane resin is an aliphatic waterborne polyurethane dispersion with a plant oil polyol content of not less than 30%; the wear-resistant reinforcing particles are a compound of nano-silica modified with a silane coupling agent and waterborne polyurethane wax slurry, wherein the mass ratio of the nano-silica modified with the silane coupling agent to the waterborne polyurethane wax slurry is 3:1; The preparation steps of the A slurry are as follows: waterborne polyurethane resin, polyether silane nonionic wetting agent, defoamer and deionized water are mixed and stirred evenly, then wear-resistant reinforcing particles are added, and the mixture is stirred until it is completely dispersed. Then, multi-tube energy aziridine crosslinking agent is added, stirred evenly and then allowed to stand to defoam for later use. The B slurry comprises the following raw materials in parts by weight: 100 parts solvent-free polyurethane prepolymer, 25 parts polyether polyol, 5 parts 1,4-butanediol, 1 part deionized water, 0.1 parts bismuth-zinc composite catalyst, 8 parts halogen-free flame retardant, and 1 part foam stabilizer. The preparation steps of the B slurry are as follows: polyether polyol, 1,4-butanediol, deionized water, bismuth zinc composite catalyst, halogen-free flame retardant and foam stabilizer are added to the mixing tank according to the weight parts, and stirred at 1500 rpm for 1 min to mix evenly and remove some air bubbles. Then, solvent-free polyurethane prepolymer is added under continuous stirring and vacuum of -0.08 MPa, and stirring is continued for 2 min to form the B slurry. (3) Coating, pre-curing and embossing: The A slurry and the B slurry are coated sequentially on the continuously conveyed release paper to obtain a release paper with a wet mixed coating. Then, the release paper with the mixed coating is pre-cured to obtain a release paper with a plastic surface and a coating. Then, the embossing roller is used to press out the texture. The pressure of the embossing roller is controlled at 3MPa. During the pre-curing process, the reactive components in the B slurry are foamed and initially cross-linked, thereby forming a mixed coating that maintains surface plasticity while having internal supporting strength. Then, the texture is embossed onto the surface of the mixed coating using an embossing roller and initially shaped. (4) The substrate is laminated with the textured coated release paper obtained in step (3), and then dried at 120-150℃ for 2-5 minutes. (5) Cool and peel off the release paper to obtain a new type of embossed basketball leather.

[0020] Example 2

[0021] Referring to Embodiment 1, this embodiment differs from Embodiment 1 in the following parameters, while other technical solutions are the same as in Embodiment 1.

[0022] Specifically, the amount of raw fiber used in the high-elasticity nonwoven fabric and the parameter control in the preparation process differ from those in Example 1. The preparation process of the high-elasticity nonwoven fabric in this example is as follows: S1, using 78 parts by weight of polyester staple fiber, 22 parts by weight of spandex staple fiber, and 2 parts by weight of antistatic agent as raw materials, the fibers are evenly dispersed by mechanical opening and airflow mixing; S2, the mixed fibers are carded into a web by a carding machine to obtain a fiber web; S3, the fiber web is conveyed to a two-roll hot rolling mill and hot-pressed and bonded under the conditions of a roll temperature of 137°C and a linear pressure of 30 N / mm, so that the fibers melt and bond at the intersection points to form a stable nonwoven fabric substrate with three-dimensional elasticity; S4, the nonwoven fabric after hot rolling is cooled and shaped by a cooling roller, and finally wound up for later use, thus obtaining the high-elasticity nonwoven fabric.

[0023] The amounts of each raw material component in the A and B slurries also differ from those in Example 1. The A slurry in this embodiment comprises the following raw materials in parts by weight: 100 parts waterborne polyurethane resin, 7 parts abrasion-resistant reinforcing particles, 2 parts multifunctional aziridine crosslinking agent, 0.4 parts polyether siloxane nonionic wetting agent, 0.2 parts defoamer, and 12 parts deionized water; the B slurry comprises the following raw materials in parts by weight: 100 parts solvent-free polyurethane prepolymer, 30 parts polyether polyol, 6.5 parts 1,4-butanediol, 2 parts deionized water, 0.3 parts bismuth-zinc composite catalyst, 9 parts halogen-free flame retardant, and 2 parts foam leveling agent; In addition, the embossing roller described in step (3) is equipped with a replaceable modular embossing roller set with different textures.

[0024] Example 3

[0025] Referring to Embodiment 1, this embodiment differs from Embodiment 1 in the following parameters, while other technical solutions are the same as in Embodiment 1.

[0026] Specifically, the amount of raw fiber used in the high-elasticity nonwoven fabric and the parameter control in the preparation process differ from those in Example 1. The preparation process of the high-elasticity nonwoven fabric in this example is as follows: S1, using 85 parts by weight of polyester staple fiber, 30 parts by weight of spandex staple fiber, and 3 parts by weight of antistatic agent as raw materials, the fibers are evenly dispersed by mechanical opening and airflow mixing; S2, the mixed fibers are carded into a web by a carding machine to obtain a fiber web; S3, the fiber web is conveyed to a two-roll hot rolling mill and hot-pressed and bonded under the conditions of a roll temperature of 155°C and a linear pressure of 40 N / mm, so that the fibers melt and bond at the intersection points to form a stable nonwoven fabric substrate with three-dimensional elasticity; S4, the nonwoven fabric after hot rolling is cooled and shaped by a cooling roller, and finally wound up for later use, thus obtaining the high-elasticity nonwoven fabric.

[0027] The amounts of each raw material component in the A slurry and B slurry also differ from those in Example 1. The A slurry in this embodiment comprises the following raw materials in parts by weight: 100 parts waterborne polyurethane resin, 10 parts abrasion-resistant reinforcing particles, 3 parts multifunctional aziridine crosslinking agent, 0.5 parts polyether siloxane nonionic wetting agent, 0.3 parts defoamer, and 20 parts deionized water; The B slurry comprises the following raw materials in parts by weight: 100 parts solvent-free polyurethane prepolymer, 35 parts polyether polyol, 8 parts 1,4-butanediol, 3 parts deionized water, 0.5 parts bismuth-zinc composite catalyst, 10 parts halogen-free flame retardant, and 3 parts foam stabilizer. The performance of the embossed basketball leather obtained in Examples 1 to 3 of this application was tested, and the results are shown in the table below:

[0028] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A novel method for producing embossed basketball leather, characterized in that, The preparation steps include the following: (1) Preparation of substrate: The substrate is a highly elastic nonwoven fabric; (2) Preparation of composite slurry: The composite slurry includes slurry A and slurry B; (3) Coating, pre-curing and embossing: The A slurry and the B slurry are coated sequentially on the continuously conveyed release paper to obtain a release paper with a wet mixed coating. Then, the release paper with the mixed coating is pre-cured to obtain a release paper with a plastic surface and a coating. Finally, the texture is pressed out using an embossing roller. (4) The substrate is laminated with the textured coated release paper obtained in step (3), and then dried at 120-150℃ for 2-5 minutes. (5) Cool and peel off the release paper to obtain a new type of embossed basketball leather.

2. The production method of a novel embossed basketball leather according to claim 1, characterized in that, The A slurry comprises the following raw materials in parts by weight: 100 parts of waterborne polyurethane resin, 5-10 parts of wear-resistant reinforcing particles, 1-3 parts of multifunctional aziridine crosslinking agent, 0.3-0.5 parts of polyether siloxane nonionic wetting agent, 0.1-0.3 parts of defoamer, and 5-20 parts of deionized water. The preparation steps of the A slurry are as follows: waterborne polyurethane resin, polyether silane nonionic wetting agent, defoamer and deionized water are mixed and stirred evenly, then wear-resistant reinforcing particles are added, and the mixture is stirred until it is completely dispersed. Then, multi-tube energy aziridine crosslinking agent is added, stirred evenly and then allowed to stand to defoam for later use. The B slurry comprises the following raw materials in parts by weight: 100 parts solvent-free polyurethane prepolymer, 25-35 parts polyether polyol, 5-8 parts 1,4-butanediol, 1-3 parts deionized water, 0.1-0.5 parts bismuth-zinc composite catalyst, 8-10 parts halogen-free flame retardant, and 1-3 parts foam stabilizer. The preparation steps of the B slurry are as follows: add polyether polyol, 1,4-butanediol, deionized water, bismuth-zinc composite catalyst, halogen-free flame retardant, and foam stabilizer to a mixing tank according to the weight parts mentioned above, stir at 1500-2000 rpm for 1-2 minutes to mix evenly and remove some air bubbles, then add solvent-free polyurethane prepolymer under continuous stirring and a vacuum degree of -0.08-0.09 MPa, and continue stirring for 2-3 minutes to form the B slurry.

3. The production method of a novel embossed basketball leather according to claim 1, characterized in that: During the pre-curing process in step (3), the reactive components in the B slurry are foamed and initially cross-linked, so that the mixed coating forms a state in which the surface remains plastic and the interior has supporting strength. Then, the texture is imprinted onto the surface of the mixed coating by an embossing roller and initially shaped.

4. The production method of a novel embossed basketball leather according to claim 1, characterized in that: The pressure of the embossing roller is controlled at 3-12 MPa.

5. The production method of a novel embossed basketball leather according to claim 1, characterized in that: Step (1) The specific preparation steps of the high elasticity nonwoven fabric are as follows: S1, using 70-85 parts by weight of polyester short fiber, 15-30 parts by weight of spandex short fiber, and 1-3 parts by weight of antistatic agent as raw materials, the fibers are evenly dispersed by mechanical opening and airflow mixing; S2, the mixed fibers are carded into a web by a carding machine to obtain a fiber web; S3, the fiber web is conveyed to a twin-roll hot rolling mill and hot-pressed and bonded under the conditions of roll temperature of 130-155℃ and linear pressure of 20-40 N / mm, so that the fibers melt and bond at the intersection point to form a stable nonwoven fabric substrate with three-dimensional elasticity; S4. The nonwoven fabric after hot rolling is cooled and shaped by cooling rollers, and finally rolled up for use, thus obtaining the high-elasticity nonwoven fabric.

6. The production method of a novel embossed basketball leather according to claim 1, characterized in that: The embossing rollers in step (3) are equipped with replaceable modular embossing roller sets with different textures.

7. The production method of a novel embossed basketball leather according to claim 2, characterized in that: The waterborne polyurethane resin is an aliphatic waterborne polyurethane dispersion with a bio-based content of not less than 30%.

8. The production method of a novel embossed basketball leather according to claim 2, characterized in that: The wear-resistant reinforcing particles are a compound of nano-silica modified with silane coupling agent and water-based polyurethane wax paste, wherein the mass ratio of nano-silica modified with silane coupling agent to water-based polyurethane wax paste is 3:

1.

9. The production method of a novel embossed basketball leather according to claim 7, characterized in that: The bio-based raw material is selected from one of the following: plant oil polyols, bio-based polyether polyols, and sugar derivative polyols.

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