Dual-Core Golf Ball Mold Assembly With Independent Temperature Control
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Solution Overview
Problem
Conventional mold assemblies for forming dual cores in golf balls lack independent and rapid temperature control of the shell forming plate and mold cavity, leading to inconsistencies in curing, which affect core durability and concentricity, resulting in performance inadequacies.
Innovation Solution
A mold assembly with independently controlled temperature platens for the shell forming plate and mold cavity, utilizing thermally cycled water for precise temperature regulation, allowing faster thermal cycling and preventing over/undercuring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mold assemblies are used for forming dual cores, then the manufacturing process is simple, but the temperature control of the shell forming plate and mold cavity is not independent, leading to curing inconsistencies
Solution Approach 1:
The mold assembly is segmented into separate temperature control systems for the shell forming plate and the mold cavity plate. Each plate has its own heating/cooling circuits, allowing independent temperature regulation. This segmentation enables precise control of the curing process at different stages, resolving the curing consistency issue while maintaining manageable system complexity through modular design.
Solution Approach 2:
Different regions of the mold assembly are given different temperature characteristics. The shell forming plate can be heated to a higher temperature to promote curing of the outer shell, while the mold cavity plate is maintained at a lower temperature to prevent premature curing of the inner core material. This local differentiation of temperature quality ensures proper curing sequence and consistency.
2Manufacturing precision
If the shell forming plate is passively heated through the mold and material, then the structure is simple, but the temperature control precision is insufficient, affecting core durability and concentricity
Solution Approach 1:
The passive thermal conduction system is replaced with an active thermal control system using electric heating elements and cooling circuits within the mold plates. This substitution allows precise temperature regulation through electrical energy input, enabling accurate control of the curing process to achieve proper core concentricity and durability, despite increased energy consumption.
Solution Approach 2:
The temperature parameters of the mold plates are actively changed and controlled during the manufacturing process. The shell forming plate temperature can be increased to accelerate curing, while the cavity plate temperature is adjusted to maintain material flow properties. This dynamic parameter control ensures optimal curing conditions for achieving precise core concentricity.
3Productivity
If conventional heating methods are used, then the equipment is simple, but the thermal cycling speed is slow, preventing rapid temperature modulation during manufacturing
Solution Approach 1:
The temperature control system employs periodic heating and cooling cycles through alternating hot and cold fluid circulation in the mold plate circuits. This periodic thermal action enables rapid temperature modulation during the manufacturing process, allowing quick transitions between heating and cooling phases to optimize curing at different stages, thereby reducing overall manufacturing cycle time.
Solution Approach 2:
Hydraulic or pneumatic fluid circulation systems are used to rapidly transfer heat in and out of the mold plates. By circulating temperature-controlled fluids through channels in the mold assembly, the system achieves fast thermal cycling capability, enabling rapid temperature changes without complex direct heating elements, thus improving productivity through efficient thermal management.
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 achieves improved core durability and concentricity, reducing center shift and enhancing manufacturing consistency by precisely controlling the curing process.
Implementation Method 1
a first platen operatively connected to the upper surface of the shell forming plate and configured to maintain the shell forming plate at a first temperature
Implementation Method 2
a second platen operatively connected to the lower surface of the mold cavity plate and configured to maintain the mold cavity plate at a second temperature that is lower than the first temperature
Implementation Method 3
the first platen is temperature-controlled by thermally cycled water
Data Source
AI summary
Mold assemblies and methods for compression molding dual cores of golf balls are provided. The mold assemblies and methods for molding dual cores allow for direct and independent temperature control of both the shell forming plate and the mold cavity plate during manufacturing of the dual cores. The shell forming plate and the mold cavity plate are temperature-controlled by independent platens. The ability to precisely control the temperature of the shell forming plate independent from the temperature of the mold cavity plate prevents under and overcuring of the outer core layer, which can adversely affect core durability, concentricity, and manufacturing yields.