Crosslinked Thermoplastic Polyurethane Golf Ball Cover

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Solution Overview

Problem

Golf ball covers made from ionomer resins suffer from poor scuff resistance and inferior spin and feel properties compared to balata rubber or polyurethane covers, while thermoset polyurethane elastomers, although offering good scuff resistance, require complex manufacturing processes, making them inefficient to produce.

Innovation Solution

A golf ball with a crosslinked thermoplastic polyurethane elastomer cover, featuring crosslinks in the hard segments formed from unsaturated bonds catalyzed by a free radical initiator, using a mixture of unsaturated diols, chain extenders, long chain polyols, and organic isocyanates, which enhances scuff resistance and manufacturing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If ionomer resin is used for golf ball cover, then manufacturing efficiency is improved, but scuff resistance deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidscuff resistance

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent uses a composite material system consisting of thermoplastic polyurethane elastomer combined with specific additives (silane crosslinking agent, free radical initiator, and inorganic filler). This composite approach maintains the manufacturing efficiency of thermoplastic materials while the crosslinking reaction and filler reinforcement significantly improve scuff resistance, resolving the contradiction between ease of manufacture and durability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the chemical structure parameters of the polyurethane elastomer by introducing crosslinks through silane modification and free radical initiation. This transforms the linear polymer chains into a three-dimensional network structure, fundamentally altering the material's surface properties to enhance scuff resistance while preserving the base material's processability.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If softer ionomer resin is used to improve spin and feel, then spin and feel properties are improved, but coefficient of restitution deteriorates

Engineering Contradiction:

Improvespin and feel propertiesVSAvoidcoefficient of restitution

Core Design Contradiction:

ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent modifies the durometer hardness parameter of the cover material to fall within the specific range of 40-70 Shore A. This optimized parameter range achieves the desired balance: soft enough to provide good spin and feel characteristics, yet hard enough to maintain adequate coefficient of restitution and resilience, resolving the trade-off between spin/feel and energy retention.

Inventive Principle:

Principle #35Parameter changes

3Strength

If thermoset polyurethane elastomer is used, then scuff resistance is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvescuff resistanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent inverts the conventional approach by using a thermoplastic polyurethane elastomer base material (which is easily processable) instead of traditional thermoset materials. The scuff resistance enhancement is achieved not through the base polymer type but through post-polymerization crosslinking and filler addition, thereby obtaining thermoset-like durability with thermoplastic manufacturing simplicity.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent incorporates the silane crosslinking agent and free radical initiator into the polymer composition during the compounding stage, before the actual molding process. This preliminary preparation allows the crosslinking reaction to occur during or after molding, eliminating the need for separate complex curing equipment or multi-step manufacturing processes required by traditional thermoset materials.

Inventive Principle:

Principle #10Preliminary action

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 crosslinked thermoplastic polyurethane elastomer provides improved scuff resistance and manufacturing efficiency, meeting requirements for compression deformation, coefficient of restitution, Shore D hardness, and flexural modulus, resulting in a golf ball with superior performance and production efficiency.

Implementation Method 1

the crosslinks being the reaction product of unsaturated bonds located in the hard segments as catalyzed by a free radical initiator

Methodology Applied

Scientific EffectFree radical initiation:

Implementation Method 2

the crosslinked thermoplastic polyurethane elastomer includes crosslinks located in the hard segments

Methodology Applied

Scientific EffectCrosslinking:

Data Source

PatentEP2402062B1Golf balls including crosslinked thermoplastic polyurethane

Publication Date: 2013.10.09 NIKE INNOVATE CV

Figure 1~4

AI summary

This disclosure relates to golf balls made from a crosslinked thermoplastic polyurethane elastomer. The crosslinked thermoplastic polyurethane elastomer includes crosslinks located in the hard segments, where the crosslinks being the reaction product of unsaturated bonds located in the hard segments as catalyzed by a free radical initiator. The crosslinks may be formed from an unsaturated diol as a chain extender. The unsaturated diol may be trimethylolpropane monoallylether (TMPME). The golf ball may include the crosslinked thermoplastic polyurethane elastomer in the cover layer, in which case the cover layer may exhibit a high degree of scuff resistance.