Crosslinked Highly-Neutralized Polymer Golf Ball Layers
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Solution Overview
Problem
The processability of thermoplastic ionomers becomes challenging as the percentage of acid group neutralization increases, limiting their use in golf ball layers despite offering enhanced resiliency and durability.
Innovation Solution
A golf ball composition incorporating a highly-neutralized polymer material with a C3-8 α,β-ethylenically unsaturated carboxylic acid, a softening monomer, and a cation source to neutralize at least 80% of acid groups, combined with a crosslinking initiator and coagent, which allows for improved melt flow and crosslinking, enhancing resiliency and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the percent of neutralization of acid groups in ionomers is increased to improve resiliency and durability, then the melt flow becomes too low and processability decreases
Solution Approach 1:
The patent applies parameter changes by modifying the chemical structure of the ionomer through specific comonomer selection (ethylene, C3-8 α,β-ethylenically unsaturated carboxylic acid, and softening monomer) and controlling the neutralization degree (60-90%) to achieve an optimal balance between resiliency/durability and processability, resolving the contradiction between these two properties
Solution Approach 2:
The patent uses composite materials by combining the highly-neutralized ionomer with a crosslinking initiator and coagent to create a crosslinked polymer composition. This composite approach maintains the enhanced resiliency and durability of high-neutralization ionomers while the crosslinking structure preserves adequate melt flow and processability
2Reliability
If the percent of neutralization of acid groups is increased to enhance resiliency, then the melt flow decreases making the material harder to process
Solution Approach 1:
The patent optimizes the neutralization degree parameter to 60-90% (rather than near 100%) and selects specific comonomers including softening monomers to maintain adequate melt flow while achieving the desired resiliency enhancement, thus resolving the contradiction between resiliency and productivity
3Reliability
If high neutralization percentage is used to improve durability, then the ease of processing the polymer composition decreases
Solution Approach 1:
The patent creates a composite material system combining highly-neutralized ionomer (60-90% neutralization) with crosslinking agents and coagents. This composite approach enables the material to achieve improved durability through high neutralization while the crosslinking chemistry and formulation maintain adequate processability during manufacturing
Solution Approach 2:
The patent adjusts the neutralization parameter to an optimal range (60-90%) rather than maximum, and incorporates specific comonomers and crosslinking agents to achieve the desired balance between durability enhancement and ease of processing
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 composition provides golf balls with increased resiliency, durability, and compression, while maintaining processability, resulting in improved performance and stability over time and at elevated temperatures.
Implementation Method 1
a crosslinking initiator and coagent, which allows for improved melt flow and crosslinking, enhancing resiliency and durability
Implementation Method 2
a cation source present in an amount sufficient to neutralize at least 80% of all acid groups
Data Source
AI summary
The invention relates to golf balls having at least one layer formed from a highly-neutralized polymer material that has been crosslinked. In particular, the compositions of the invention include a highly-neutralized polymer, at least one crosslinking initiator, and at least one coagent. The invention also relates to methods of making the compositions and golf ball constructions that incorporate the compositions of the invention in at least a portion thereof.