Fusible spherical skin structure and its manufacturing method

Abstract

This invention provides an easily fusible ball skin structure and its manufacturing method. The easily fusible ball skin structure includes a substrate layer, a first polyurethane adhesive layer, a polyurethane core layer, a second polyurethane adhesive layer, and a thermoplastic polyurethane surface layer. The first polyurethane adhesive layer is disposed on the substrate layer. The polyurethane core layer is disposed on the first polyurethane adhesive layer. The second polyurethane adhesive layer is disposed on the polyurethane core layer. The thermoplastic polyurethane surface layer is disposed on the second polyurethane adhesive layer. Compared with the prior art, the easily fusible ball skin structure of this invention can achieve rapid welding between ball skins, which not only improves production efficiency and saves a lot of labor costs, but also makes the ball's appearance appear seamless. In addition, the easily fusible ball skin structure of this invention, through the combination of the thermoplastic polyurethane surface layer and the polyurethane core layer, can significantly improve the overall feel.

Claims

1. A fusible ball skin structure, comprising: Substrate layer; A first polyurethane adhesive layer is disposed on the substrate layer; a polyurethane core layer is disposed on the first polyurethane adhesive layer, the polyurethane core layer comprising an unfoamed thermosetting polyurethane layer, a first foamed thermosetting polyurethane layer, and a second foamed thermosetting polyurethane layer, wherein the second foamed thermosetting polyurethane layer is disposed on the first polyurethane adhesive layer, the first foamed thermosetting polyurethane layer is disposed on the second foamed thermosetting polyurethane layer, and the unfoamed thermosetting polyurethane layer is disposed on the first foamed thermosetting polyurethane layer, wherein the foaming pore size of the first foamed thermosetting polyurethane layer is 50-150 µm; a second polyurethane adhesive layer is disposed on the unfoamed thermosetting polyurethane layer of the polyurethane core layer; and a thermoplastic polyurethane surface layer is disposed on the second polyurethane adhesive layer.

2. The fusible ball structure of claim 1, wherein the substrate layer comprises fabric, fiber product or film.

3. A fusible ball skin structure, comprising: Substrate layer; A first polyurethane adhesive layer is disposed on the substrate layer; a polyurethane core layer is disposed on the first polyurethane adhesive layer, the polyurethane core layer comprising an unfoamed thermosetting polyurethane layer, a first foamed thermosetting polyurethane layer, and a second foamed thermosetting polyurethane layer, wherein the second foamed thermosetting polyurethane layer is disposed on the first polyurethane adhesive layer, the first foamed thermosetting polyurethane layer is disposed on the second foamed thermosetting polyurethane layer, and the unfoamed thermosetting polyurethane layer is disposed on the first foamed thermosetting polyurethane layer, wherein the foaming pore size of the second foamed thermosetting polyurethane layer is 300-500 µm; a second polyurethane adhesive layer is disposed on the unfoamed thermosetting polyurethane layer of the polyurethane core layer; and a thermoplastic polyurethane surface layer is disposed on the second polyurethane adhesive layer.

4. A method for manufacturing an easily fusible spherical skin structure, comprising: (a) Forming a polyurethane core layer on a first surface of a release paper, wherein the polyurethane core layer has an upper surface in contact with the first surface of the release paper and a lower surface relative to the upper surface; wherein forming the polyurethane core layer in step (a) includes: (a1) applying an unfoamed thermosetting polyurethane layer to the first surface of the release paper; (a2) applying a first foamed thermosetting polyurethane layer to the lower surface of the unfoamed thermosetting polyurethane layer, wherein the foaming pore size of the first foamed thermosetting polyurethane layer is 50-150 µm; and (a3) ​​applying a second foamed thermosetting polyurethane layer to the lower surface of the first foamed thermosetting polyurethane layer; (b) attaching a substrate layer to the lower surface of the polyurethane core layer by a first polyurethane adhesive layer; (c) removing the release paper to expose the upper surface of the polyurethane core layer; and (d) attaching a thermoplastic polyurethane surface layer to the upper surface of the polyurethane core layer by a second polyurethane adhesive layer to obtain the fusible ball skin structure.

5. A method for manufacturing a fusible ball-shaped structure as claimed in claim 4, wherein step (b) includes attaching the substrate layer to the lower surface of the second foamed thermosetting polyurethane layer of the polyurethane core layer via the first polyurethane adhesive layer; step (c) includes exposing the upper surface of the unfoamed thermosetting polyurethane layer of the polyurethane core layer; and step (d) includes attaching the thermoplastic polyurethane surface layer to the upper surface of the unfoamed thermosetting polyurethane layer of the polyurethane core layer via the second polyurethane adhesive layer.

6. The method for manufacturing the fusible ball skin structure as claimed in claim 4, further comprising: Repeat steps (a) to (d) to obtain another fusible ball skin structure; and perform high-frequency welding on the fusible ball skin structure of step (d) and the other fusible ball skin structure.

7. A method for manufacturing a fusible ball skin structure as claimed in claim 6, wherein the fusible ball skin structure has a first thickness, the other fusible ball skin structure has a second thickness, and the third thickness after high-frequency welding is less than the first thickness and the second thickness.

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