Air-Cured Golf Ball Core Using Oxygen-Permeable Mold
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Solution Overview
Problem
Conventional peroxide cure systems for golf ball elastomeric compositions are inhibited by oxygen, leading to incomplete cure and poor durability, requiring high coagent levels that complicate the manufacturing process and increase costs.
Innovation Solution
Incorporating a mixture of elastomeric compositions and organic peroxide-based curing compositions that can cure without additional coagents, using specific additives like bis-maleimides, amino acids, and sulfur-containing compounds, allowing the golf ball to contact oxygen during curing without inhibiting the curing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional peroxide cure systems are used for elastomeric compositions, then the golf ball core achieves good heat stability and compression set, but oxygen inhibition occurs during curing leading to incomplete cure and poor durability
Solution Approach 1:
The patent introduces oxygen-permeable mold materials (silicone rubber, fluorosilicone rubber, or their blends) as intermediaries between the oxygen environment and the elastomeric composition. These mold materials selectively permit oxygen transmission while maintaining mold integrity, enabling complete peroxide curing without oxygen inhibition. The mold material acts as a mediator that transforms the harmful oxygen environment into a beneficial curing condition.
Solution Approach 2:
The patent changes the oxygen permeability parameter of the mold material from impermeable (conventional) to permeable (silicone/fluorosilicone rubber). This parameter change allows oxygen to reach the elastomeric composition during curing, converting the oxygen inhibition problem into an oxygen-assisted curing solution. The mold material's oxygen transmission rate is specifically selected to optimize curing while preventing surface defects.
2Manufacturing precision
If high levels of coagent are added to prevent oxygen inhibition, then complete curing is achieved, but the manufacturing process becomes more complex and costs increase
Solution Approach 1:
The patent extracts the oxygen inhibition problem from the curing system by using an oxygen-permeable mold. Instead of adding coagents to chemically counteract oxygen inhibition, the solution removes the inhibiting effect entirely by allowing controlled oxygen access. This extraction approach simplifies the formulation by eliminating or reducing coagent requirements while maintaining curing completeness.
Solution Approach 2:
The elastomeric composition performs self-curing through peroxide decomposition facilitated by oxygen diffusion through the mold. The system uses the mold's oxygen permeability to enable the curing reaction without requiring external addition of coagents or complex catalytic systems. The oxygen from the environment serves the curing process directly, making the system self-sufficient.
3Ease of manufacture
If oxygen is present during peroxide curing, then the curing process is inhibited and material sticks to the mold, but using oxygen-impermeable molds creates demolding difficulties and surface defects
Solution Approach 1:
The oxygen-permeable mold material serves as an intermediary that reconciles the conflicting requirements of demolding ease and cure completeness. It allows oxygen transmission to prevent sticking while maintaining sufficient mold integrity for demolding. The mold material's specific oxygen permeability and elastic properties mediate between these opposing demands, enabling both complete curing and easy demolding.
Solution Approach 2:
The patent changes multiple parameters of the mold material simultaneously: oxygen permeability (from impermeable to permeable), elasticity (to facilitate demolding), and thermal properties (for proper curing). These parameter changes in the mold material enable it to support complete peroxide curing while allowing easy demolding without surface defects on the golf ball core.
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 enables complete curing of the elastomeric compositions, preventing sticking and tearing during demolding, resulting in a durable golf ball with improved physical and mechanical properties without the need for additional coagents, thus simplifying the manufacturing process and reducing costs.
Implementation Method 1
peroxide curing systems display greater heat stability, better compression set, and ability to achieve vulcanization without using ingredients that are known to be harmful or produce an inferior resulting core/golf ball
Implementation Method 2
ability to achieve vulcanization without using ingredients that are known to be harmful
Implementation Method 3
oxygen undesirably reacts with elastomer radicals formed, and depolymerizes the rubber/elastomer
Implementation Method 4
Incorporating a mixture of elastomeric compositions and organic peroxide-based curing compositions that can cure without additional coagents, using specific additives like bis-maleimides, amino acids, and sulfur-containing compounds, allowing the golf ball to contact oxygen during curing without inhibiting the curing process
Data Source
AI summary
Golf ball comprising at least one layer that is comprised of an air-cured elastomer composition comprising an elastomer and an organic peroxide curing agent.