Thermoplastic Polyurethane Ball Texture via Ultrasonic Welding
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Solution Overview
Problem
Current methods for producing basketballs are energy-intensive, inefficient, and environmentally unfriendly due to the need for vulcanization and waste generation during the production of PU and rubber layers, leading to increased costs and pollution.
Innovation Solution
A method involving a thermoplastic polyurethane ball texture production process that includes heating and foaming, extruding, roll pressing, embossing, cutting, welding, and carving steps, utilizing ultrasonic welding and biodegradable thermoplastic foaming materials to create a durable and efficient ball texture without vulcanization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vulcanization is used to combine PU layer and rubber layer, then durability and stability are improved, but energy consumption increases and production time is extended
Solution Approach 1:
The invention changes the bonding mechanism from chemical vulcanization to mechanical interlocking through groove structures. The PU layer is formed with grooves that mechanically interlock with the rubber layer, eliminating the need for vulcanization while maintaining bonding strength and durability.
Solution Approach 2:
The invention extracts and removes the vulcanization process from the production line, replacing it with a mechanical groove-interlocking system. This eliminates the energy-intensive heating and chemical treatment steps while achieving the same bonding function.
2Reliability
If vulcanization is used to combine layers, then stability is improved, but production time is extended
Solution Approach 1:
The invention changes the bonding mechanism from time-consuming chemical vulcanization to immediate mechanical interlocking. The groove structures provide instant mechanical bonding when layers are assembled, eliminating the hours required for vulcanization cycles.
Solution Approach 2:
The groove structures are pre-formed in the PU layer during its extrusion process, so that when the rubber layer is added, the mechanical interlocking occurs immediately without requiring additional bonding time or chemical reactions.
3Productivity
If traditional PU casting method is used, then production capability is achieved, but waste generation increases
Solution Approach 1:
The invention replaces the traditional PU casting process with extrusion technology. Extrusion is a more efficient mechanical process that forms the PU layer directly with minimal material waste, eliminating the need for casting molds and the associated flash and scrap generation.
Solution Approach 2:
The invention changes the manufacturing process from batch casting to continuous extrusion. This parameter change enables continuous production with better material utilization, reducing waste while maintaining or improving production capability.
4Ease of manufacture
If multiple separate processes (adhesion, lamination, cutting) are used to combine rubber and PU layers, then assembly is achieved, but production efficiency decreases and costs increase
Solution Approach 1:
The invention merges multiple separate processes (adhesion, lamination, cutting) into a single integrated extrusion process. The groove structures are formed during extrusion, and the mechanical interlocking provides both bonding and structural functions simultaneously, eliminating multiple production steps.
Solution Approach 2:
The groove structures serve multiple functions simultaneously: they provide mechanical interlocking for bonding, create the ball's three-dimensional shape, and eliminate the need for separate cutting and assembly operations. This multi-functionality improves production efficiency while maintaining assembly capability.
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
This process reduces energy consumption, shortens production time, minimizes waste, and enhances environmental sustainability by using biodegradable materials and ultrasonic welding, resulting in a more efficient and cost-effective production method with improved durability and feel for basketballs.
Implementation Method 1
a heating and foaming step (900)
Implementation Method 2
the thermoplastic polyurethane is foamed by way of an added vesicant
Implementation Method 3
the partial overlapping region of two adjacent connecting sheets is welded by way of ultrasonic welding
Data Source
Figure 1
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Figure 3
AI summary
A thermoplastic polyurethane is foamed by way of an added vesicant and is then extruded to provide a thermoplastic forming material (3). The thermoplastic forming material (3) is roll pressed to provide an unfinished sheet, and a surface of the unfinished sheet is embossed for printing a predetermined drawing to provide an embossed sheet. The embossed sheet is cut to provide plural connecting sheets, and the partial overlapping of two adjacent connecting sheets is ultrasonically welded to provide a connected exterior. At least one groove (34) is cut in the predetermined drawing surface of the exterior to provide a ball texture.