Multilayer Composite Ball Structure with Stepped Bonding
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Solution Overview
Problem
Existing elastic ball structures, primarily made from rubber or plastic, have complex manufacturing processes, high quality control difficulties, and a high rejection rate, requiring frequent inflation and thus necessitating the purchase of an inflation device.
Innovation Solution
A multilayer composite high-elastic ball structure with a base layer and multiple coating layers, featuring stepped or concave-convex surfaces for secure bonding, and a fabric layer for enhanced strength and elasticity, eliminating the need for inflation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rubber or plastic materials are used for elastic balls, then the balls can achieve basic elasticity, but the manufacturing process becomes long and complicated with high quality control difficulty and high rejection rate
Solution Approach 1:
The ball is divided into multiple functional layers (base layer, first coating layer, second coating layer, third coating layer, fourth coating layer) with each layer having specific thickness ranges and material compositions. This segmentation allows independent optimization of each layer's properties, simplifying the overall manufacturing process while ensuring quality stability through controlled layer-by-layer construction.
Solution Approach 2:
The invention uses composite material structure combining different foam materials (PU, EVA, TPE, SBR, NBR, EPDM, POE, PE, TPR) and leather layers with specific elasticity moduli ratios. The base layer has elasticity modulus of 0.5-2.0 MPa, first coating layer 2-5 MPa, second coating layer 5-10 MPa, third coating layer 10-20 MPa, and fourth coating layer 20-50 MPa, creating a graded composite structure that improves reliability while managing manufacturing complexity through standardized material selection.
2Duration of action of stationary object
If traditional elastic ball structures are used, then basic functionality is achieved, but frequent inflation is required necessitating purchase of inflation device
Solution Approach 1:
The ball structure is pre-designed with multiple dense coating layers (first, second, third, and fourth coating layers) with increasing elasticity moduli that provide inherent structural integrity and airtightness. This preliminary structural reinforcement eliminates the need for subsequent inflation operations, extending the duration of action without inflation while improving ease of operation by removing maintenance requirements.
3Strength
If simple single-layer structure is used, then manufacturing is simple, but strength and elasticity are insufficient
Solution Approach 1:
Each layer is assigned specific local properties: base layer (0.5-2.0 MPa) for core elasticity, first coating layer (2-5 MPa) for structural support, second coating layer (5-10 MPa) for enhanced durability, third coating layer (10-20 MPa) for strength reinforcement, and fourth coating layer (20-50 MPa) for surface integrity. This local quality differentiation achieves high overall strength while managing complexity through standardized layer specifications.
Solution Approach 2:
The ball structure employs a nested multi-layer configuration where the first coating layer surrounds the base layer, the second coating layer surrounds the first, the third coating layer surrounds the second, and the fourth coating layer surrounds the third. This nested arrangement maximizes strength through layered reinforcement while maintaining a unified spherical structure, balancing strength enhancement with manageable structural complexity.
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 solution simplifies manufacturing, enhances stability and reliability, provides high strength and long service life, and eliminates the need for inflation, resulting in a cost-effective and durable ball structure.
Implementation Method 1
a first bonding layer (6) arranged between an inner surface of the second coating layer (3) and an outer surface of the first coating layer (2) for bonding the second coating layer with the first coating layer
Data Source
AI summary
The utility model discloses a multilayer composite high-elastic environmentally-friendly ball structure which comprises a base layer, a first coating layer, a second coating layer, a third coating layer and a fourth coating layer, wherein both the base layer and the first coating layer are formed by splicing a number of pieces into a hollow spherical structure, and a contact surface of two adjacent spliced pieces is a stepped surface in a “Z” shape or a concave-convex fitting surface in a “U” shape. The utility model have the advantages of simple manufacturing process, novel design, high stability, high reliability, high elasticity and long service life.