Two-Layer Leak-Proof Ball with Bromobutyl Mucilage Inner Layer
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Solution Overview
Problem
Traditional sports balls, particularly laminated basketballs, are prone to leaks over time due to air tightness issues, reducing their service life and user experience.
Innovation Solution
A dual-layer leak-proof design incorporating a sheath layer, intermediate body layer, winding yarn layer, and a protective layer made of air-sealing bromobutyl mucilage, which is injected into the inner body layer and vulcanized to ensure air tightness and reinforce the inner structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional single-layer inner bladder is used, then the manufacturing process is simple, but the air tightness deteriorates over time leading to leaks
Solution Approach 1:
The inner bladder is segmented into two distinct layers: an inner layer made of bromobutyl rubber and an outer layer made of natural rubber. This segmentation allows each layer to perform its specific function - the bromobutyl layer provides superior air tightness while the natural rubber layer provides durability and structural support, thereby resolving the contradiction between air tightness and structural integrity without excessive complexity
Solution Approach 2:
The patent employs composite materials by combining bromobutyl rubber and natural rubber in a layered structure. The bromobutyl rubber layer provides exceptional air tightness properties, while the natural rubber outer layer provides mechanical strength and durability. This composite approach directly addresses the contradiction by achieving high reliability through material composition rather than increasing overall structural complexity
2Duration of action of stationary object
If a traditional single-layer inner bladder is used, then the structure is simple, but the service life is reduced due to leaks
Solution Approach 1:
The inner bladder is divided into functional segments with the bromobutyl rubber layer specifically dedicated to air retention and the natural rubber layer to structural support. This functional segmentation extends service life by ensuring that the air tightness function is handled by the most suitable material, preventing leaks that would otherwise limit the ball's usable lifetime
Solution Approach 2:
By using composite rubber materials with distinct properties in each layer, the patent achieves extended service life through optimized material performance. The bromobutyl rubber's superior air tightness prevents premature failure from leaks, while the natural rubber provides long-term structural durability, together significantly extending the ball's service life without requiring overly complex multi-component systems
3Reliability
If bromobutyl mucilage is injected into the inner body layer, then air tightness is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The bromobutyl rubber is prepared as a ready-to-inject mucilage formulation before the manufacturing process. This preliminary preparation of the material in a suitable state allows for straightforward injection into the molded natural rubber layer, enhancing air tightness without requiring complex manufacturing steps. The mucilage form ensures proper adhesion and distribution within the outer layer
Solution Approach 2:
The patent employs injection technology to introduce the bromobutyl rubber mucilage into the outer rubber layer. This pneumatic/hydraulic injection method allows for precise and controlled placement of the air tightness layer within the manufacturing process, achieving enhanced reliability through a relatively simple and efficient manufacturing step rather than complex multi-stage processes
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The dual-layer design significantly enhances the air tightness and service life of the ball, providing a more reliable and durable playing experience by preventing leaks and maintaining air pressure.
Implementation Method 1
vulcanized to ensure air tightness and reinforce the inner structure
Implementation Method 2
bromobutyl mucilage...vulcanized to ensure air tightness
Data Source
AI summary
A two-layer leak-proof ball comprises a sheath layer (1), an intermediate body layer (2), a winding yarn layer (3), an inner body layer (4) and a two-layer protective layer (5). The intermediate body layer (2), the winding yarn layer (3), the inner body layer (4) and the two-layer protective layer (5) are tightly set successively at the inside of the sheath layer (1). Also disclosed is the manufacturing method of the two-layer protective layer (5) of the two-layer leak-proof ball. High air-sealed bromide butyl mucilage is injected at the inside of the inner body layer (4), and vulcanized at low temperature, thus a glue film is formed at the inner wall of the inner body layer (4). The inner bag of the two-layer leak-proof ball has high tightness and long service life.