Multi-layered Golf Ball Core with Foam Inner Layer
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Solution Overview
Problem
Golf balls with foam cores tend to have low resiliency, resulting in shorter distances and reduced performance, as they absorb impact rather than transferring energy effectively.
Innovation Solution
A multi-piece golf ball design featuring a foamed inner core, a thermoplastic intermediate layer, and a thermoset outer core layer with specific gravity and hardness gradients, optimized with polyurethane and polybutadiene compositions to enhance resiliency and energy transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a foam core is used in a golf ball, then the ball absorbs impact and appears softer, but the resiliency and rebounding performance deteriorate
Solution Approach 1:
The core is divided into multiple layers with different material properties: an inner foam core layer for impact absorption, an intermediate thermoplastic layer for energy transfer, and an outer thermoset layer for durability. This segmentation allows each layer to perform its specific function optimally without compromising the others.
Solution Approach 2:
The golf ball core uses a composite structure combining foam material (for cushioning), thermoplastic polymer (for energy transfer), and thermoset polymer (for durability). This composite approach integrates the beneficial properties of each material while mitigating their individual drawbacks.
2Device complexity
If a foam core is used in a golf ball, then the ball structure is simplified, but the flight distance and performance deteriorate
Solution Approach 1:
The core is segmented into functional layers: the foam inner core provides structural simplicity and impact absorption, while the surrounding thermoplastic and thermoset layers add energy transfer and durability functions, respectively. This segmentation maintains relative structural simplicity while improving performance.
Solution Approach 2:
The thermoplastic intermediate layer acts as a mediator between the foam core and outer thermoset layer, transferring energy from the impact to the outer layers and improving flight distance while maintaining the simplicity of the foam core structure.
3Strength
If a foam core is used in a golf ball, then the ball is more durable in terms of impact resistance, but the rebound velocity and energy transfer deteriorate
Solution Approach 1:
The core is segmented into an inner foam layer for impact resistance and an outer thermoset layer for high rebound velocity. The foam layer absorbs impact forces, while the thermoset layer provides the elastic recovery and high rebound velocity, with the thermoplastic intermediate layer facilitating energy transfer between them.
Solution Approach 2:
The composite structure combines foam (for impact resistance), thermoplastic (for energy transfer), and thermoset (for rebound velocity) materials. Each material contributes its specific property to the overall performance, achieving both impact resistance and high rebound velocity simultaneously.
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 design improves the golf ball's coefficient of restitution, allowing for higher initial ball speed and longer distances while maintaining durability and control.
Implementation Method 1
an inner core (center) made of a foam composition
Implementation Method 2
an intermediate layer disposed about the inner core and made of a thermoplastic composition
Implementation Method 3
an outer core layer disposed about the intermediate core layer and made of a thermoset composition
Data Source
AI summary
Multi-layered golf ball core sub-assemblies and the resulting golf balls are provided. The core structure includes an inner core (center) comprising a foam composition, preferably foamed polyurethane. The intermediate core layer is preferably formed from a thermoplastic composition such as an ethylene acid copolymer ionomer resin; and the outer core layer is preferably formed from a thermoset composition such as polybutadiene rubber. The core layers have different hardness and specific gravity levels. In one preferred embodiment, the inner core has a positive hardness gradient, the intermediate core has a positive hardness gradient, and the outer core has a zero or negative hardness gradient. The core structure and resulting ball have relatively good resiliency.