Dual-Core Golf Ball with Foam Center and Plasticized Thermoplastic Outer Layer
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Solution Overview
Problem
There is a need for improved core constructions in golf balls that provide a combination of toughness, resiliency, and optimal properties such as feel and spin control, without being excessively hard or stiff, which existing compositions fail to achieve effectively.
Innovation Solution
The use of a dual-core golf ball design with an inner core made from a foamed or metal-containing composition and an outer core layer made of a plasticized thermoplastic composition, featuring a positive hardness gradient across the core assembly, utilizing an acid copolymer of ethylene and an α,β-unsaturated carboxylic acid with a plasticizer and a cation source to neutralize acid groups, allowing for a combination of Coefficient of Restitution (CoR) and compression properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional ionomer polymers are used for the core layer, then durability and toughness are improved, but the ball becomes excessively hard and loses feel and spin control
Solution Approach 1:
The patent applies local quality by creating a dual-layer core structure where the inner core and outer core layer have different material compositions and hardness levels. The inner core uses traditional ionomer polymer for toughness, while the outer core layer uses a softer material to provide feel and spin control. This allows each layer to perform its specific function optimally without compromising the overall ball performance.
2Power
If multi-layered core structures are used, then resiliency and initial velocity are improved, but the construction complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the core into distinct layers - an inner core and an outer core layer, each with specific material compositions and functions. This segmentation allows optimization of each layer for specific performance characteristics (resiliency, toughness, feel) while maintaining a manageable construction that can be manufactured using conventional processes.
3Ease of operation
If softer materials are used in the core, then feel and spin control are improved, but durability and toughness decrease
Solution Approach 1:
The patent applies local quality by creating a dual-layer core structure where the inner core and outer core layer have different material compositions and hardness levels. The inner core uses traditional ionomer polymer for toughness, while the outer core layer uses a softer material to provide feel and spin control. This allows each layer to perform its specific function optimally without compromising the overall ball performance.
Data Source
AI summary
Multi-layered golf balls containing a dual-core structure are provided. The core structure includes an inner core (center) made from a foam or metal-containing composition, or it has a hollow shell construction, and the outer core layer is made of a thermoplastic composition. Preferably, the thermoplastic composition comprises: a) ethylene acid copolymer, b) plasticizer, and c) cation source. A fatty acid ester such as ethyl oleate is preferably used as the plasticizer. The core assembly preferably has a positive hardness gradient extending across the entire assembly. The core structure and resulting ball have relatively good resiliency at given compressions.